When I left off on the package shelf I was waiting for a saw from a buddy. I could have chewed the speaker holes like a beaver by the time I got the saw! Anyway, I got it this week and got right on the shelf.
With the holes cut I moved onto getting the pieces ready to create the rollover to the rear seatback. I cut down paint sticks with a utility knife against a straight edge, then pinched them all together and sanded them all to the same width. Not really the optimal way to do this but the paint sticks were free and already here so....
Next I drilled the holes for the speaker grill screws then used 3 M spray adhesive and stuck the speaker box material to the hardboard shelf.
Then the time consuming process of attaching the rollover. I decided to rivet the strips to pinch the vinyl rollover and carpet material. Holes through the paint sticks were drilled. The pieces were clamped in place and the holes for the rivets were melted with a mini soldering iron through the vinyl and carpet. This prevents the material from wrapping up on the drill bit. Then the holes were drilled through the hardboard. Once the holes were set I inserted rivets in each to keep the pieces aligned while I pulled each rivet and used washers on the backside so the rivets wouldn't pull through the hardboard.
A section of padding was glued to the rollover similar to the original and gives the rollover a factory look. The rear seatback holds the rollover down when it's installed in the car. I left extra material on the ends and will trim to fit when I put the shelf in the car.
I looked around for some black machine screws for the speaker grills but didn't have any so I splurged and bought some new ones for a whopping $1.88 LOL The only cash spent to build the shelf was 6-7 bucks for a sheet of hardboard and the screws. With the speaker grills installed the shelf is ready! I may use some dum dum or other deadener to be sure the rivets or speaker grill bolts don't rattle when it's installed in the car.
