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Old 02-28-2012, 01:38 AM   #1 (permalink)
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Trunk Expansion Kits

I'm looking to expand the storage in my trunk a bit and I don't have the know how to roll my own expansion. After searching the forums, the only vendor that I can find who currently offers a kit is Dark Water Customs. [link]

It's a perfectly good kit, but I was hoping to find a few different choices. Does anyone know of any other trunk expansion kits?

Thanks
Doug
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Old 02-28-2012, 02:50 AM   #2 (permalink)
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It is either Dark Water's version or the DIY version.
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Old 02-28-2012, 03:06 AM   #3 (permalink)
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Good Quality with the Dark Water approach.
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Old 02-28-2012, 03:06 AM   #4 (permalink)
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I've seen a couple examples of DIYers, but I don't remember seeing a build post or plans for doing it.
(did I miss it?)
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Old 02-28-2012, 03:15 AM   #5 (permalink)
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Quote:
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I've seen a couple examples of DIYers, but I don't remember seeing a build post or plans for doing it.
(did I miss it?)
I did my own. Just made a cardboard template and went to a buddies shop to bend it up.





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Old 02-28-2012, 03:26 AM   #6 (permalink)
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Here is my DIY job. It was quite the custom fit job to say the least.

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Old 02-28-2012, 05:29 AM   #7 (permalink)
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Nice DIY Mods

Those are real nice DIY trunks!
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Old 02-28-2012, 12:03 PM   #8 (permalink)
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Here's my DIY. Mine is a Mk3 so it is configured a little differently than your later Mk4 with the raised floor but the concept is the same:







I chose not to cut out the structural tubing but even with it in place I can still fit two helmets within the triangles or put all kinds of soft bags and other stuff under or around it. Expanding the trunk is one of the best mods you can do in my opinion.

Good luck,
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Old 02-28-2012, 04:53 PM   #9 (permalink)
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If you choose the DIY route, here's a few more pix of a MkII.

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Old 02-28-2012, 05:22 PM   #10 (permalink)
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Here's my attempt - this was one of the reasons I got a welder - the first cut is the hardest, once you cut your first 3/4" tube, the rest is easy! To be honest, I don't think FFR puts enough reinforcement around the gas tank - I cut those bars out that you can see in the above pictures, but added considerably more protection around the gas tank. I think I have some more pics somewhere if you want to see them...

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Old 02-28-2012, 05:46 PM   #11 (permalink)
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I Did It Too (To My MK-II)

Here is a shot of my modified trunk. I re-worked the structure to be just above the fuel tank for the floor.

I also made the rear bulkhead go up to the body which made the area above the differential a cockpit accessible storage area.

The horizontal strip in the front of the trunk floor is the cover to my "Deep Well" trunk area which is the full width of the chassis and goes down to be just above the bottom of the differential. It fills the space between the differential and the fuel tank.

I also did the "full drop butt mod" and cut the original horizontal tube, at the back, down for an easier "lift over" access to the trunk.

Regards, Rick.

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Old 02-28-2012, 07:24 PM   #12 (permalink)
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Check with Cobra Earl. He did a super "Touring" trunk mod on my MK1.
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Old 02-28-2012, 07:34 PM   #13 (permalink)
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Here's mine. Did it a week ago. Take measurements, cut, bend, repeat.

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Old 02-29-2012, 04:49 AM   #14 (permalink)
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Those do look great. I'll need to think about this.

I'd love to be able to reconfigure the trunk but I can't weld and don't have a break or shear to do the metal work, although those all seem like fixable issues.

Thanks for the inspiration guys!
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Old 02-29-2012, 11:43 AM   #15 (permalink)
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Quote:
Originally Posted by Zippyfoo View Post
I'd love to be able to reconfigure the trunk but I can't weld and don't have a break or shear to do the metal work, although those all seem like fixable issues.

Thanks for the inspiration guys!
You can leave the crossbars in place, as many of us have, and then there is no welding needed.

I cut the sheetmetal using an angle grinder with cut off wheel. For the bend, I clamped it down with a 2x4 and used a hand seamer to get the bend started:

6" Jaw Straight Sheet Metal Seamer

The finished it off by hitting it with a rubber mallet.

Mine isn't the nicest, but it will be covered in carpet so the ugly gets hidden.
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Old 02-29-2012, 03:14 PM   #16 (permalink)
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Cobra Earl sells a nice trunk expansion kit. Involves cutting out pieces of trunk cross-bar, but his kit includes the pre-bent pieces of aluminum. I did not re-weld anything as I'm not a welder.

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Old 02-29-2012, 05:31 PM   #17 (permalink)
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I would show you mine, but it is not nearly as pretty as the others above. Not being a welder myself, I went around the cross tubes as stated above. Used a 2x4 as my own break. It is passable and will be covered with carpet and a piano hinged plate...It is one of those places you can experiment a little on these cars and not really hurt anything.
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Old 02-29-2012, 09:00 PM   #18 (permalink)
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Same as JKleiner's above. There are pics here somewhere of mine, I think.
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Old 02-29-2012, 10:22 PM   #19 (permalink)
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Here is where Iím going with mine. However, this takes a lot of measuring and angle figuring. Iím working on a diagram layout to put out there for anyone else who wants to give this a shot, but my job has had me so tied up Iím running about a month and a half behind on this. I will put it out as soon as I get the welding done and can show just where everything goes and how involved it gets.
Good luck with your mods.

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Old 03-01-2012, 02:34 AM   #20 (permalink)
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Not trying to high jack this thread. Looking at the DWC trunk boxes, it looks like they will drop into a completed car. Can anyone confirm this.

Thanks,
Perry
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Old 03-02-2012, 04:29 AM   #21 (permalink)
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You guys inspired me! Thanks!
Trunkbox template version 1.0.
version 1.1 coming tomorrow.

starts getting a little tricky when you start thinking about putting multiple bends on a single piece, and then having to install the whole thing within the existing braces. I'm hoping I don't need to drop the tank.
I think the mk4 box is a little shallower.
did anyone run a brace across the bottom? (underneath) the bottom seems kinda bouncy.

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Old 03-02-2012, 11:33 AM   #22 (permalink)
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I added framework under.





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Old 03-02-2012, 12:59 PM   #23 (permalink)
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Mark, you're really good with paper & scissors. Want to come over and cut one up for my trunk?
Looks like the brake is going back into use.

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Old 03-02-2012, 01:14 PM   #24 (permalink)
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Old 03-02-2012, 01:33 PM   #25 (permalink)
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Well done Mark! Even if you have to drop the tank you won't regret it. I used the same .040 6061 as the FFR panels and it has been plenty firm for my purposes.

Jeff

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Old 03-02-2012, 01:52 PM   #26 (permalink)
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here's mine...to start-

24" long x 10 1/2" wide x 5" deep when done...I hope
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Old 03-02-2012, 02:00 PM   #27 (permalink)
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Quote:
Originally Posted by MPTech View Post
You guys inspired me! Thanks!
Trunkbox template version 1.0.
version 1.1 coming tomorrow.

starts getting a little tricky when you start thinking about putting multiple bends on a single piece, and then having to install the whole thing within the existing braces. I'm hoping I don't need to drop the tank.
I think the mk4 box is a little shallower.
did anyone run a brace across the bottom? (underneath) the bottom seems kinda bouncy.

If you use 1/8" plate for the bottom, it will stiffen it up.
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Old 03-02-2012, 05:08 PM   #28 (permalink)
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Added Under Structure

Quote:
Originally Posted by MPTech View Post
You guys inspired me! Thanks!
Trunkbox template version 1.0.
version 1.1 coming tomorrow.

...
did anyone run a brace across the bottom? (underneath) the bottom seems kinda bouncy.

...
I made some structure to support the trunk floor area. I made it so I could do most of the welding outside of the chassis area, for convenience of work space.

Regards, Rick.

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Old 03-02-2012, 07:14 PM   #29 (permalink)
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I am also looking to mod my trunk. Cobra Earl indicated to me that he doesn't do trunk mod kits anymore. He did not want to get stuck with inventory that wouldn't fit the MKIV. I have been watching Harbor Freight for a brake and they now have their 30" brake on sale for $35 through their inside track club. See picture for coupon, this sale is for the month of March. I think I will give it a shot to make my own footbox, F-Panel and trunk mods.

Rick, I like your idea of making the trunk brace changes outside and then just attaching the assy. I already have a powder coated frame and the rear end/3 link in. Do you have any pics of the chassis before you put this in ( what you cut out)?
Thanks, Bill
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Old 03-02-2012, 07:22 PM   #30 (permalink)
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I have been watching Harbor Freight for a brake and they now have their 30" brake on sale for $35 through their inside track club.
I have used that brake in the past - it's about $34 overpriced. So long as you are bending real thin aluminum, and don't want a nice sharp bend, it's sort of works.
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