The next step was the rear panels. As the Pacer is now a pickup the back must be all new to fit the Volvo wagon hatch window and surrounding area. So out comes the cardboard and it’s template time again. Templates are not difficult to do they just take a little time, thought and a utility knife. I needed to make one main panel that would handle the area below the window and two side sections that would extend to the headliner, as they would need to be angled forward a bit.
I use tape to fill in areas where to much of the template has been cut out. It is a process of cut and fit several times until you’ve got the shape you want. Once the main template shape is done it’s time to measure the speaker, courtesy light and wiring cutouts.
Once the temlate is done I set it over the 1/4″ plywood sheet and mark and cut it out. Check one more time to make sure the cut panel fits, make a few adjustments and it’s ready to be covered.
Once done it looks great and is ready for install. I will do that next week along with the building the side panels. I will also be building a subwoofer box at the center of the main panel, over the hump. The amp will set on top of the subwoofer box.