Well my Guide on Headlights went down a treat, so here's one for boot builds-
Stage 1- Preperation
As Always Preperation is the key to success.
The first thing to do is decide on the style of install you want, to get an idea of what works have a look around, there ar eloads of thread on the subject, use the search function located at the top of the page.
I personally chose my design because it is pretty challenging, but the rewards are an easy to see boot build which looks excellent.
Once you have decided on design, it is time to get all materials sorted out, It is not a cheap thing to do unless you already have the neccessary tools etc...
The first choice is which size of MDF, originally i was worried about weight and wanted to use 12mm but then i seen how flexxy it was and to be honest i want a sturdy build, i dont want it collapsing if i hit a pothole or something. So i decided to go for 18mm. This can be bought for £10.99 a sheet in BnQ Warehouse. 2 sheets is EASILY enough for ANY Saxo Install. I also needed 2 metres of 2x2" timber to use as supports for my false floor, the timber was £2.99. I also thourghouly recommend LOTS of cardboard, test all sizes with cardboard so you dont waste any wood.
Next thing is get all tools and equipment sorted, here's the essentials you will need-
Wood Saw
Jigsaw
Cordless Drill
Electric Sander
Philips Screwdriver
Flat Head Screwdriver
Stanley Knife
Tape Measure
Hammer
Spirit Level
Pad Saw
Pencil
1.5"x8 Wood Screws
2"x8 Wood Screws
3"x8 Wood Screws
Now that you have everything ready and you are confident of your plans it is time to begin the fun.
Stage 2- Cutting All Pieces to Size
Wear a Dust Mask To Cover Your Mouth. I Didnt and have HUGE Chapped Lips To Show For My Stupidity!!!
Part 1- Base Size of MDF Needed- 42.5x26"
First Thing to do is mark out the base, to do this remove the liners from bottom of boot, the bottom "foam" type one is a perfect template for the base. Put it on top of MDF and mark around it with a pencil.
Then Place wood on a Bench and cut round with a Jigsaw.
You will now need to take a check out of each side of the base at the rear to allow it to fit over the bolts for rear seats. It will then fit in perfectly.
Part 2- Supports 2x2" Timber Needed
Next step is to make the false floor, 3" is the perfect height. For the support i used 2x2" Timber. Cut Ten 3" long pieces.
Part 3- Sides Size of MDF Needed- 57x40.5cm
* Cut a piece of MDF, 57x40.5cm.
* Measure 9.5cm up from the 57cm long side, and draw a straight line across. The line should be 56cm.
* On the Line Mark points at 12cm and 25cm accross. Mark at same intervals at top of MDF and draw the straight lines.
* From the second line there should be 31cm, Now make a mark 3cm in from this side, a line is not needed.
*Now mark out the angles by drawing in the diagonal lines as so-
*Now cut with a jigsaw along the diagonals.
* also take appropriate checks out to fit over bolts in back of boot.
That is the sides complete.
Part 4- False Floor Top Size of MDF needed- 40.5x24.75"
It is now time to complete the false floor. To do this measure the internal Width between two MDF side panels, it will be 40.5" at widest part. The Length is 24.75" at longest part. To get the curve use the foam used in
Part 1, however you need to position it an inch off at either side as Foam will be 2" wider (42.5" instead of 40.4").
Once you have marked it all and cut it, place a few of
Part 2 randomly dotted about on top of
Part 1, then place the new false floor on, if you have marked out and cut correctly it will fit perfectly.
Part 5- Front Panel Size of MDF Needed- 106x41.5cm
Once Panel is cut, place it in, this is how Finished install will look as far as shape and size goes.
Stage 3- Putting it all together
Attaching False Floor To Base
First thing to do is attach 10 of
Part 2 onto the base, i attached them leaving the centre completely free as this is where i will be putting my amps.
To attach them use 3" Wood screws. Make sure they are all very tight.
Next stage is place the base back in the boot along with the sideloosely in place.
Now put something sticky and wet
on top of each
Part 2, i used bicycle grease. Now place the base on top.
Leave for a few seconds and then remove.
The grease acts as a mark for where to screw the base down onto the supports.
Where all the grease is you need to drill a small hole using a 2mm drill bit.
Then flip over and put back in boot, leaving sides loose in boot so you srew it down in correct places.
Using 3" wood screws, screw through all the holes-
Attatching the Sides
Now it is time to mark the sides.
To do this make marks on both the sides and the false floor at same places, make 2 marks on each side.-
Now remove it all from boot, place on a stand and line it up again, then fix it all together using 2" Wood screws, You need to fix it from side and from bottom, as so-
It should now look like so-
Stage 4- Marking Out Front Panel
To do this is fairly simple, here what i done-
My sub diamater hole was 11inch. The total Length was 42".
I was using 2 subs.
2x11= 22
42-22=20
20/4= 5
So i went 5" in from each side, then 11" from the 5" mark, leaving 10" space in the middle (im considering putting in a changer)
So now mark lines up and down for the sizes.
It is now time to get the hieght right.
I wanted to play it safe and make sure subs didnt hit the false floor so i left more space at bottom than i did at top.
To work out the space i done following-
Total hieght- 16.5"
Then took away the sub diameter (11") form this.
Leaving 5.5".
I measured 3" up form bottom and drew a line right accross and 2.5" down from top and drew a line right accross,
As so-
Now use your Sub cutting template and mark on.
cut one to be safe and try for size-
How To- Custom Boot Build **Update**
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