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garystockton · Posted: Sun Apr 12, 2009 23:07 Post subject: 120 Series Rear Door Table

Saw this originally on pradopoint.com and thought it would be an interesting little project - I'm usually a bunch of thumbs when it comes to this. Anyway, decided to have a go. Some of you might have heard me mumbling about not having a tail-gate while in Wales, and how I missed it's varied functionality, not having an 80-series anymore Crying or Very sad

So I decided to have a play

Raw Materials:
12mm plywood, 1100mm x 500mm
self-tapping screws, nylon hooks, stainless marine hinges, 20mm webbing strap, 3mm shock cord; 500ml spray-on upholstery glue. Most of the stuff came from B&Q except the carpet, marine stainless steel hinges and hooks, which cam from various flea-bay suppliers, mostly Chandlery World (excellent stuff ...)

Decided to varnish the ply and trim the front corners. I didn't like the wood effect, so then decided to cover the ply with car carpet (the stuff used to cover speaker boxes, etc.:

Got SWMBO to help with the fabric cutting (well, what do I know about mitred corners: Razz

). Fully covered table. NB: Ensure the glue you use dries to be transparent - the stuff I got doesn't, so had to be careful with gluing

Figuring out the hinge layout:

Oooh - drilling holes in the rear door moulding - ouch!! Trap the folded over 20mm webbing under the nylon hooks and screw it all down with 30mm self-tappers...

Marking up and drilling for the centre hinge - drill right through the steel - ensure no clips etc. are in the way:

Table fitted!!

Table folded away for travel:

Anyone for tea??

Worthwhile exercise - SWMBO thinks it's great! Total cost, about £30 - I paid more in total, because I had to buy a roll of carpeting, a whole tin of varnish, whole tin of glue etc... some of which will be reused on other exciting projects (next up is a packing system...). I had fun, though!

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uk_vette · Posted: Sun Apr 12, 2009 23:51 Post subject:

I have thought of an excellent use for the glue, and carpet you still have over. Laughing

When shal I bring mine Very Happy

garystockton · Posted: Mon Apr 13, 2009 10:53 Post subject:

Actually, if you forego the varnishing and sanding step, you can probably do all this on a Saturday afternoon. In hindsight, I think the 20mm webbing is too narrow - I couldn't find any 25mm webbing though, and wanted this complete by next weekend!

I think the 25mm would be screwed into the holes under the 4 hooks, as opposed to just being trapped under them - may be more secure that way. But then, this is not meant to be a seat, so should be OK - time will tell!

uk_vette · Posted: Mon Jun 08, 2009 13:48 Post subject:

Hi Gary,

This is my next mod.
I have mulled over this for a while, and now is the time to start getting all the bits.

I have various bits already, including the webbing, which is 25mm.

I have to go to B&Q later to take back some brackets what I was going to use for the roof rack, (but got better and stronger ones )

'vette