Mike B

Nice job Jerry. I admire your persistence and dedication. Well done!

Jerry Feather

Hi Mike. Thanks for the encouragement.

When I woke up this morning I realized that I Probably need to go ahead and work the form over further to form these liner halves a little shorter front to back. I realized after working it over yesterday that I can do that and not have to start from scratch.

When I get off work today I'm going to take it apart enough to allow me to shorten it on one side enough to form these about 3/4 inch shorter. I think that is going to be just about the right amount to allow these to be installed to most of the original points without making any of them over.

If Nicole is right, that would turn into a lot of extra work and cost that I don't want to take the time for and I am sure that many will prefer not to have to modify thier 928 any more than necessary, if at all, to install these liners. Now is the time to bite the bullet and get er done, correctly. I am going to feel a whole lot better about these when the fit right out of the form--after trimming, of course.

Jerry Feather

Tom in Austin

Keep going Jerry!

Jerry Feather

I went shopping at lunch time today to get some idea of what to use for the seal between the outer and the inner halves of these liners. I had been thinking of 1/8th inch closed cell foam, but what I have used in the past does not have much memory and tends to take a set once it is put in place rather that continuing to push out to keep a seal tight.

What I found is some 3/16 inch closed cell foam weather strip that is 1 1/4 inch wide. I was hoping for something about an inch wide, but this seems to be the standard for a seal between a pickup bed and a camper/topper. If I leave the space between the two liners at one eighth inch and allow for about a sixteenth of crush I think this will work just great. Too, in making the inner half a litte narrower and still wanting the outer half to be fairly wide, I had thought this morning that rather than an inch and a half of over lap, I will go for inch and quarter. That seems like a coincidence, but it also eliminates the need for me to put masking tape of the outer liner in order to line them up together for marking the connection points.

I think it is nice when these things come together like this. I hope my progress continues to be this successful. Now to work the form over.

Jerry Feather

Jerry Feather

I found that I didn't put quite enough material on for the change I am making in this first form for the inner half of the liners. I'm going to add a little more tonight; but then I wont get back to this project until sunday because we are going out of town for most of the weekend. I think I'll get home early sunday afternoon and can get some more time in on it.

One thing I think I can use right now, or pretty soon, is a measurement from someone's GTS. I need to know just how tall the two little mounting point are in the very top of the wheel well. I can figure out their location from the used-up liners I got from Tony, and I can probably guesstimate just about how tall they are, but a more exact measurement will be helpful. Anyone? Thanks.

Jerry Feather

Tom in Austin

Glad to Jerry, just let me know exactly what you need

Jerry Feather

Hi Tom.

The top two mounting points for mounting the liners in the GTS are like little boxes affixed to the top of the inner wheel well area. I think they are affixed to the part of the car body that is inside of the baggage area and beneath the inner rear quarter panels.

All I need to know in exactly (within a sixteenth of an inch) how tall they are from the body downward to the surface that the original liners screw to. I think they are between an inch and an inch and a half "tall." Tall means from their mounting on the car downward, as if they were standing erect but in the southern hemisphere. Everybody down under is standing tall, but to the rest of us they are pointing downward.

I hope that clears it up. Thanks in advance for looking into it for me. I hope you don't have to go to a lot of trouble to get the measurement. If this involves taking your liners out, please don't do it now. Let's wait for someone like Tony who doesn't have liners to remove to get the measurement.

Jerry Feather

Rob Edwards

I have no liners in right now and will be playing in the garage this evening, if measurements have not been posted by then.

Jerry Feather

Thanks Rob. I think that is going to save Tom some trouble. Jerry Feather

Bill Ball

So, when can I order a set for the right side of my S4?

Nice job, Jerry!

Rob Edwards

Jerry:

Here are a couple of quick n dirty shots, sorry for the parallax error on the rulers. If these are not accurate enough, let me know and I can get the depth gauge on the slide caliper out.

You will see that the ‘height’ of the bracket depends on where you measure, so if these are the rong places from which to measure, holler.

Left side brackets:



Front brackets:


Front bracket, front edge. the measurement depends, of course, on where along the edge you measure:







Rear brackets:





Right side brackets:


Front bracket, front edge::






Front bracket, rear edge::



Rear bracket:

Jerry Feather

Thanks Rob, for going to this much trouble on this. The pictures are great and the measurements will help a bunch if I am able at all to develop the upper mounting system without an actual GTS to work with. Thanks again.

Jerry Feather

Jerry Feather

Thanks Bill. I am hoping soon, but I still have to develop the rest of the form for the outer halves of these, and that will be a more complex form because it will have two interchangable components so that I can use it to make the two different versions of these liners.

As I mantioned earlier in this thread, I have a surgery scheduled oin my right knee (torn meniscus) on the 20th and I think I will not be able to workl on this stuff for at least a week, unless I can do anything on it on crutches; I'll have to see.

I am wondering why, except for the cost, that you will be expecting to buy only half a set? If that is going to be fairly common and if it is equally divided between left and right, I might consider that approach. However, if there is some reason that a bunch of owners are going to want just the right side only I wonder what I would do with all of the left over left side liners?

Jerry Feather

soontobered84

Jerry,
If anything, you would want to make more for the left side since the PSD (which should be serviced regularly)is behind the left cover. Since there would be more jostling and removing for the left, it stand to reason that the left side would break,crack and generally hve more opportunity to deteriorate more than the the right

nc_growler

Yep! Exactly! But I wouldn't be upset if he only sold matching pairs...