ALIEN ENCLOSURES 67-69 CAMARO AND FIREBIRD Trunk Panel Kit Instructions TYPICAL TOOLS & MATERIALS NEEDED FOR UPHOLSTERY 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 Phillips screwdriver, Heat Gun/Hair Dryer, Spray Adhesive, Staple Gun LIGHT KITS WILL REQUIRE: 1 Piece of 1/2 finish grade plywood. Final piece will be 56 1/2 x 14 1/4. Approx. (30) 7-7/16 backing panel framing screws (For attaching inserts, and / or backing panels with associated kit. Approx. (30) 1 Fine Thread Drywall screws (for attaching braces and mounting blocks). Approx. 8.5 ft. of Hook & Loop strips enough for (15) 6 strips and (1) 12 strip (B&C).
Congratulations and thank you for the purchase of your new Camaro / Firebird 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 DIF- FER 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 Marked Floor 5) Six 6 X 1 Square braces for the ends of the floor Panel, Panel A & Panel B 6) One 12 X 1 Angled brace for the center of the C Panel, (Handle C Panel with care until 12 brace is attached) 7) Ten 6 X 1 Angled braces. Two for the C Panel, Eight for the floor Panel 8) One Package of 1 Fine Thread Drywall screws (for attaching braces) UN-UPHOLSTERED KITS - INCLUDED MATERIALS: (SOME QUANTITIES AND ITEMS MAY DIFFER DEPENDING ON DESIGN 1) Backing Panels / Inserts with letters the same as their coordinating panels (i.e. A-BP = Panel Backing Panel, AN = Panel A Insert) (Quantity may differ by design) 2) One Package of (30) 7-7/16 backing panel framing screws (For attaching inserts, and / or backing panels with as sociated kits 3) 9 ft. of Hook & Loop strips enough for (15) 6 strips and (1) 12 strip (B&C). (Panels can also be permanently attached) UN-UPHOLSTERED LIGHT KITS Light kits will include most of the previously mentioned items. Items not included are: 1) One Floor Panel Marked Floor 2) All mounting hardware * Instructions for Floor Fabrication are included in the next section with diagrams at the end of the instructions. *A-BODY IMAGES USED IN MOST OF THE INSTRUCTIONS - ASSEMBLY IS SIMILAR
LIGHT KIT FABRICATION: If you have purchased one our Light kits, you will need to fabricate the Floor panel. Please refer to last page of instructions for hole drilling diagram and brace layout. You will need to cut or have cut a piece of 1/2 finish ply plywood for the floor. The floor size is: 56-1/2 X 14-1/4 ASSEMBLY: Some kits will be partially assembled. You will need to complete the assembly of Panel A, B & Floor Panel Panel A has two 6 Square Braces. Use the 1 Fine Drywall screws for this installation. (Figure 1). Blocks will be mounted to the upholstered side of the panel, with the Velcro facing inward. Panel B has two 6 Square Braces. Use the 1 Fine Drywall screws for this installation. (Figure 2). Blocks will be mounted to the upholstered side of the panel, with the Velcro facing inward. (Figure 1) The Floor Panel has two 6 Square Braces. Use the 1 Fine Drywall screws for this installation. (Figure 3). The floor panel also has 4 angled block on each side. Blocks will be mounted to the carpeted side of the panel, with the Velcro facing inward.
ASSEMBLY: Some kits will be partially assembled. You will need to complete the assembly of Panel A, B & Floor Panel Un-upholstered kits Panels B&C can be permanently attached or left separate by using Velcro strips. Most kits will be partially assembled. Screws and Velcro is provided. (Figure 4). 67/68 Kits will require additional assembly of the fuel filler hump that is attached to the B Panel. See 67/68 Addendum for details TEST FIT / INSTALLATION SEQUENCE: You will quickly learn the sequence of the panel assembly. The first few times follow these easy steps: Place your floor panel in the trunk first. 67/68 models have a fuel filler recess that will need to be aligned with the fuel neck hump. (Figure 5) 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 6) (Figure 5) (Figure 6)
The panel must be aligned on the left and right with the floor panel. (Figure 7) 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 8) (Figure 7) (Figure 8) 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 9) (Figure 9) *Un-upholstered Kits 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.
UPHOLSTERY: There are actually several different ways to upholster the panels. In the photos shown; the inserts (N) were left out and the backing panels (BP) 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. Depending on your chosen upholstery style, you will need to upholster backing panels. Evenly space over opening from behind and use the 7-7/16 framing screws to attach approx 6 apart from each other. We have also found the addition of a permanent glue, (like Gorilla Glue) works great! (Figure 10) (Figure 10) 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. (Figure 11) 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 blocks and panels. (Figure 11 ) (Figure 11)
UPHOLSTERY 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 7/16 screws with small beads approx 6 apart.
67-68 Fuel Hump Instructions: The 67 and 68 F-Bodies had the fuel filler in the rear tail panel vs. behind the license plate in 69. So in order to allow for that, you will find additional pieces to assemble and upholster. Below are the diagrams of how the three pieces of the hump are assembled. We recommend glue and staples, however drywall type screws can be used to assemble. This hump and the B panel will need to be upholstered first then assembled together by using drywall style screws from the back of the B panel. We strongly recommend a test fit with hardware prior to upholstering. Be sure to align B Panel with floor to confirm proper alignment before attaching hump, as the floor hump is not centered.
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: dacostadesigns@yahoo.com OR 813 841 0834 We hope you enjoy your new trunk kit Thanks! Keep an eye out for our new custom package tray kits