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Old 01-05-2020, 06:39 PM   #1
Churchkey
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5/8 plywood covered with frost king sticky one side duct insulation. Tabs are 1/2 x 1/2 .050 aluminum angle the pieces requiring radius were done in a manual shrinker used #8 x 1/2 sheet metal screws to attach.

Floor will get insulation & glued down carpet in front of the hole, will hold the rear of the carpet down with Velcro for quick access.
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Old 01-05-2020, 08:25 PM   #2
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nice work, going to look great.
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Old 01-07-2020, 06:31 PM   #3
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Ripped wood fillers from scrap 1x6 for the angle channels in the floor & glued them in then insulated the area.

Wheel wells will get Naugahyde covered vertical side boards then covered shelfs from the side boards to the inner 1/4's.

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Old Yesterday, 09:40 AM   #4
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Old Yesterday, 10:35 AM   #5
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Its interesting what Churchkey did here in his wagon (eliminating the cargo plywood). I'm curious if others have used a 'filler' to flush up where the indentations are
in the cargo area of a wagon. If so, what did you use and how did it work out?
I suppose the reason is to eliminate the plywood thickness from the cargo floor?

I think the factory used the cargo plywood to 'level' the cargo space and left the indentations underneath open.
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Old Yesterday, 11:04 AM   #6
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The wires to the rear of the car go in a gap between the plywood & left wheelhouse. I guess Churchkey is going to run them under the car or through a conduit.
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Old Yesterday, 05:34 PM   #7
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Build criteria for this vehicle is function over form it is a only a utility vehicle it has a class 3 trailer hitch & it will have a roof rack.

I consider the added plywood over the floor to be redundant the car has a steel floor the upper shock mounts have been removed & plated over + I do not want to make another floor & a hinged trap door + all of the trim required around the edges. There will be a small "bump" in the carpet where the relief for the fuel tank breather hose is located it is a non factor for me my SUV does not have a flat floor it has never been an issue.

I may move the rear wiring under the car depending on fit / clearance @ the left tailgate jam for the wheel house side board. If the side board will fit the rear wiring (new) will remain in the stock location on the floor a 1x2 will be attached to the left wheelhouse to space the left wheel house side board out & cover the wiring. Am not concerned about loosing width in the cargo area the car is to narrow to haul sheet rock or plywood.

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Old Yesterday, 10:20 PM   #8
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That should quite that old wagon down inside.
Mine rattles like a tin can.
No headliner and no insulation on the floor , just carpet.
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Old Today, 10:34 AM   #9
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Tin Can is exactly what my ol woman named this one, no guts other than front seats she rode in it once maybe twice & complained.
Had an old house throw rug, threw it on the car floor, the dog kept looking for it
I put it back in the house for him.
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Old Today, 11:08 AM   #10
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