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Make your own custom rear parcel shelf

Written By Nevyn for SquaredArches.com

  • Applies To: All variants of VN
  • Example Vehicle: VN Executive
  • Estimated Time In Beers:
  • Tools Required: Jigsaw, staple gun, sharp stanley knife, long straight edge, orbital sander & cordless drill
  • Parts Required: MDF board (1800 x 600 x 16mm), fabric of your choice & a can of spray adhesive.

Often the first modification done by new owners of a VN is to replace the stereo. Chances are if it has the original unit it isn't much cop and if it was aftermarket, the seller usually removes the speakers. One of the most popular speaker choices is 6x9s on the rear shelf, however this usually results in utlising speaker pods which look out of place or cutting into the structure beneath the parcel shelf which can lead to defects and the subsequent heartache.

Whether you are looking at upgrading your speakers or just looking to add to the visual impact of your system, a custom parcel shelf is a good way of adding clearance and making your car stand out from the crowd. Once you've got the basics down, your imagination is the only limit to how you can dress the install up.

Thanks to Nevyn, we have the following how to available which should go a long way to saving you some money at the trimmers and also give you the sense of achievement that getting your own hands dirty provides.

  
Start off by tracing the outline of the original shelf. Obviously the more care taken with measuring your new shelf will result in a better finish. You don't want to make it too small and be forced to head back the hardware shop for more MDF.
Cut excess timber off the end and put this aside for the spacers. Using a jigsaw and a steady hand cut the curved shape to match the back windscreen.
With a sander bevel the curved edge of the board to allow for the slope of the back windscreen. This may take a number of passes and some time as it is best to keep checking the fit in the car till you are happy with it. Also its a good idea to sand the corners underneath the board as the metal curves up on either side just under the corners of the glass.
With the board fitting nicely in the curve of the glass, mark out where the backseat meets the board and attaches and again cut off the excess.
At this stage it is good to measure and mark how far back from the edge the speakers would need to sit.

Next is to sand a recess into the wood at either end so to be able to attach a pair of original sides from a VS parcel shelf.

The reason for using the sides of a VS parcel shelf is that the VS item sits higher than the VN shelf and this will give us more clearance for the speaker magnets.

You can use either a sander or a router to create the recess. A router would probably be quicker and easier if you have access to one but if not don't stress as a sander does just as good a job.
With having the shape and size right it was time to cut the holes for the speakers and the spacers. You can buy a pair of MDF spacers unpainted fairly cheap, but you will have more than enough left over to cut your own.
 
When cutting these out its a good idea to drill a 10-12 mm hole just beside the line your going to cut to allow for the jigsaw blade (do this on the waste wood side). Take your time!
Then using spray on adhesive, glue a square of parcel shelf carpet to the spacer. When this is dry and set fold the carpet over and staple it in place. Use a sharp Stanley knife to trim the excess and make it as neat as possible.
With the spacers finished it's time to fit the sloping sides. Attach these with the spay adhesive then when dry & set staple it along the full length for added strength.
Next, spray the whole board with glue and lay the carpet down. Again, take your time to ensure the carpet goes down smooth and you don't end up with any lumps n' bumps. You may find it easier to grab a mate and have them hold the carpet tight as you fix it to the board
With a sharp Stanley knife and taking your time with a steady hand, trim the outside of the carpet and cut the carpet to expose the speaker holes.
With the spacer & speaker, do a check to make sure it all fits right, then screw the spacer into place in a way the screws can't be seen.

Then when your happy with it, fit the shelf and hook up the speakers. It's a good idea to bolt or screw the board down to avoid vibration at high bassy volumes. One way of this is to use the child restraint bolts- there are 3 anchor points built into the parcel shelf.

Refit the backseat and enjoy.