ALIEN ENCLOSURES GM A-BODY Trunk Panel Kit instructions
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1 ALIEN ENCLOSURES GM A-BODY Trunk Panel Kit instructions TYPICAL TOOLS & MATERIALS NEEDED FOR UPHOLSTERED KITS 2 Yards of Main Panel Material 1.5 Yards of Backer Material 3 yards of foam backing material (Optional) headliner material suggested 2 Yards of automotive carpet Tools need would include: Razors, Sandpaper, #2 Philips screwdriver, Heat Gun/Hair Dryer, Spray Adhesive, Staple Gun
2 Congratulations and thank you for the purchase of your new A-Body custom trunk panel kit! As you can see there are multiple pieces to your kit. You will want to verify that no pieces are missing and none of them are damaged. Please let us know if there are any discrepancies. Also, you will notice there are holes on each panel without obvious purpose. These are necessary screw wholes required during the CNC process to secure panels to the cutting bed. They are placed where they will not interfere with the assembly or the finished product. Finally take care removing items from the package and handling the. We try to lightly sand the edges of all pieces; however you may still be susceptible to splinters if you run your hand or fingers along the edges. A more detailed sanding may be preferred. UPHOLSTERED & UN-UPHOLSTERED KITS - INCLUDED MATERIALS: (SOME QUANTITIES AND ITEMS MAY DIFFER DEPENDING ON DESIGN) 1) One Front Design Panel (towards front of vehicle) Marked A 2) Two Rear Panels (Rear of vehicle) Marked B & C 3) Two Side Panels Marked D & E 4) One Floor Panel 5) Three Bottom 15 x 1.5 Floor braces 6) Ten Square 6 X 1 Braces (May be attached in some kits) 7) Eight Angled 6 x 1 Braces (May be attached in some kits) 8) One Angled 12 x 1 Brace (May be attached in some kits) 9) One Package of 1.15 Fine Thread Drywall screws (for attaching side braces) UN-UPHOLSTERED KITS - INCLUDED MATERIALS: (SOME QUANTITIES AND ITEMS MAY DIFFER DEPENDING ON DESIGN
3 ASSEMBLY: Upholstered kits will be partially assembled, Only certain steps will apply. The 15 floor braces are installed on the bottom side Floor Panel. Use the 1.15 Drywall screws for these three braces. These braces fittment change after upholstering, however remember the upholstery/carpet will be tighter at first and become compact with time and heat (Like new door seals) (Figure 1) (Figure 1) The Floor Panel has two Square 6 Braces. Use the 1.15 Fine Drywall screws for this installation. (Figure 2) Blocks will be mounted to the carpeted side of the panel, with the Velcro facing inward. (Figure 2) Panel A has two Square 6 Braces. Use the 1.15 Fine Drywall screws for this installation. (Figure 3). Blocks will be mounted to the upholstered side of the panel, with the Velcro facing inward. (Figure 3 )
4 Un-upholstered kits Panels B&C can be permanently attached or left separate by using Velcro strips (Upholstered kits). There are four 6 angled blocks and one 12 angled block (mounted in center). Take care handling the C panel as the center is fragile until secured with 12 block. Screws and Velcro are provided. (Figure 4) (Figure 4 ) Panel B has two Square 6 braces. Use the 1.15 Fine Drywall screws for this installation. B&C will need to be permanently attached. (Figure 5 ) Blocks will be mounted to the upholstered side of the panel, with the Velcro facing inward. (Figure 5 ) You will now test fit and apply shims or rubber feet under floor braces to ensure firm fit. TEST FIT / INSTALLATION SEQUENCE: You will quickly learn the sequence of the panel assembly.the first few times follow these easy steps: First place floor panel with beveled braces towards the rear. Center the panel on the hump for the fuel filler neck on the trunk floor pan. (Figure 6) (Figure 6 )
5 (Figure 6 is no longer used) Second install the front panel (A). This may be the trickiest panel to install. You will want to center between the deck lid hinges with the TOP FIRST. The top edge goes just under the deck lid seal channel. (Figure 7) (Figure 7 ) The panel must be aligned on the left and right with the floor panel. (Figure 8) (Figure 8 ) Next install the rear panels (B&C). These should already be attached. This panel installs easily from the rear of the vehicle by inserting one side first into side quarter panel cavity. Align with the floor panel on the ends (Figure 9) (Figure 9 )
6 Finally install each of the side panels. These must be installed top rear first (thin pointed end of side panel). You may need to shift the floor and rear panels slightly to make each of the edges touch (they will touch with adjustment). (Figure 10,11) (Figure 10 ) Once you have finished the test fit of the panels, you may need to trim some of the panels. This can be done with a sharp utility knife or power saw and/or sander. Trim as necessary. Remove bracing blocks before upholstery. Mark each of the blocks with identifying marks for proper re-attachment. (Figure 11 ) UPHOLSTERY: There are actually several different ways to upholster the panels. In the photos shown; the inserts were left out and the backing panels were covered with an alternate fabric. You may prefer to cover the panel and backing panel together with a tight wrapped and glued style where the covering material is stretched and pressed into the recesses. Another method would be to cover the inserts with an alternate material or with the same material as the main panel to give it a tucked look.
7 Depending on your chosen upholstery style, you will need to upholster backing panels. Evenly space over opening from behind and use the 3/8 screws to attach approx 6 apart from each other. (Figure 12) (Figure 12 ) After all pieces are upholstered, affix hook & loop strips to the bracing blocks with both sides affixed (the opposite piece attached). This will align the opposite piece with the fixed piece. Remove the panels slowly to keep second hook & loop piece attached. If it comes loose, you may need to measure and re-fix. We strongly suggest using staples to aid in the attachment of the hook & loop to each of the (Figure 13 ) blocks and panels. Fittment note for 68/69 models: While all pieces are precision cut, there will be the need to remove some material from panel C on 68 and 69 models as shown in (Figure 14) (Figure 14 )
8 TIPS: 1. Test fit your pieces first to check for trimming (DO NOT ADHERE HOOK & LOOP AT THIS TIME) 2. It may be necessary to place shims or rubber feet under floor braces to ensure a firm fit of panel A 3. If you are covering with a thick material, you may need to trim the bottoms of the panels check first 4. Remove attached support blocks before covering 5. Check the penetration of your staples on a test piece of material we suggest ¼ or shorter - preferably 5/32 (available online) 6. We might suggest using a professional strength hot-glue or wood glue when re-attaching bracing blocks. You may also want to consider staples as well. 7. We strongly suggest stapling the hook & loop in several spaces on each side of each tape to prevent the release of the tape 8. You may want to consider using smaller pieces of hook & loop on the side panels for easier release. These panels can be somewhat difficult to remove when completely adhered. 9. When removing side panels place one hand on the top of the panel and another at he bottom rock the panel bottom out first (reverse of install). You may want to use a paint key to grasp the bottom of the panel to pull outward. 10. We suggest using a foam backed vinyl (thin 1/4 or less). It tends to keep the vinyl tight and can hide imperfections. However, our first kit did not have it. If you decide not to use the foam, we suggest spraying your material with spray adhesive prior to stretching over panels to prevent sag 11. You may want to reinforce the backer panels to the main panels with hot glue in addition to the 3/8 screws with small beads approx 6 apart.
9 We are always looking to improve this product and instructions. Please let us know if you may have suggestions. We also would love to see photos of your installed upholstered kits! We can be reached at anytime with questions or concerns (photos) at: OR We hope you enjoy your new trunk kit Thanks! Keep an eye out for our new custom package tray kits
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