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Old 11-17-2012, 07:47 PM   #2
Scooby Specialist
Member#: 276382
Join Date: Mar 2011
Chapter/Region: NWIC
Location: Seattle, Wa
2005 SaaBeeru


First, remove the lower back seat if you have a WRX or other wagon that the seats do not lay completely flat and lay down large pillows to protect the upper seat and reduce stress on its hinge:
Next you will need to make a template of the entire cargo area from the cardboard. You will need to leave a 1/2" gap for the side panels to fit. The tighter you keep it to the side, the more 'cupping' you will have, which may not be a negative if you're carrying something that can spill. Try to make the lines you cut as straight as possible, even on slightly curved areas, the tabs for the sides will need to fold on a straight line after all:
Lay down the plastic sheeting and cut off 2 7'4" pieces of Vinyl. For other wagons/hatches, you need 2 pieces the length of the cargo area plus 2 feet:
Cut a strip 4 'ribs' wide off of one of the pieces. If you're OCD and need your seam perfectly in the middle, you can cut several pieces of smaller length out of the main roll:
Lay down the strip and run a glue line down each side and join your floor pieces together:
You will need to put a long board or boards with weights on top down the length of the seam an allow to dry overnight (I used a shelf). For this DIY, assume that all gluing needs to cure for a full day:
After drying, lay down the template and draw a chalk outline , leave equal amounts of extra material at each end. Cut out the vinyl when finished and make sure to save the pieces you cut out for your strut tower:
For the sides you need to cut a new piece of vinyl out of the roll approximately 8" shorter than the floor piece. Cut this piece right down the middle, which will be right on one of the vinyl ridges:
You now need to slowly bend this piece along the side of your cut floor template, marking and cutting out tabs to glue. The tabs should be 1 1/2 ridges deep:
Start gluing at the tab in the middle of the strut towers and allow to dry overnight with weight on top:
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