Homemade boot floor (again)

frasreid · Post by **frasreid** » Sat Nov 30, 2019 12:44 pm

Inspired by a previous post by PJM I have manufactured a boot floor for my 4drive FR Sport. I started with a sheet of 12mm plywood £17 and some car carpet from Amazon £13.43.
To make the floor, I started by laying the plywood on two tressels. I placed the original floor carpet from the car on top of the plywood, with one side flush with the edge of the plywood. I then traced the carpet onto the plywood. I measured the additional length that I needed to cover the overlap required on the front and rear ledges, then cut the plywood using a circular saw and jigsaw. I sat the floor in place to check for fit and found that when the cut plywood was sitting on the four corners of the existing floor, it looked like it wood flex under load. I then screwed packers to the front and rear underside to prevent this. (Shown in pictures). I then slid a steel rule down the side of the new floor to measure what height the side supports would need to be, remembering to deduct the 12mm depth of the plywood. All the packers and side supports were screwed to the floor. I tried it for size again and it was fine however when I folded the rear seats down, they were rubbing on the edge of the plywood. I removed it and cut another 10mm of the back edge and tried it again and it was fine. I then covered the plywood with the carpet stapled underneath, fitted a couple of loop handles cut from the carpet to assist removal, and all is good. I hope this explains how I did this and may help somebody else. It cost me about £30 and a few hours of my time. And I still have half a sheet of plywood left for something else.

frasreid · Post by **frasreid** » Sat Nov 30, 2019 12:45 pm

Remaining pictures.

KerryB · Post by **KerryB** » Sat Nov 30, 2019 4:27 pm

Very nice! I might have a go at that. Thanks for the detailed description and great photos.

frasreid · Post by **frasreid** » Sat Nov 30, 2019 4:59 pm

Your welcome. I just noticed what appears to be sand coloured mark's on the cloth. It was actually the sun shinning behind me.

Twed701 · Post by **Twed701** » Wed Dec 04, 2019 10:18 am

Top job mate! was this just to give you a higher boot floor or are you gonna install a sub woofer? haha

frasreid · Post by **frasreid** » Thu Dec 05, 2019 1:20 am

No suby lol. It was to give me an area to store small items like shopping bags small tools etc. whilst keeping the main boot area tidy. And to raise the floor slightly.