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Old 06-18-2010, 10:56 PM   #9 (permalink)
RobertSmalls
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Join Date: Aug 2008
Location: Buffalo, NY, USA
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Prius C - '12 Toyota Prius C
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I'm taking notes and planning my own boattail construction in my head. There are large areas at the back of the Insight that have little structure, but there's pretty good stiffness around the perimeter of the hatch.

I think I will unbolt the center bumper cover retainer and attach the frame of my tail extension there. I will also get the bumper rebar involved. A few pieces of aluminium angle attached to those two components should be plenty to support a 3' long cargo floor with a 150lb weight capacity. This sturdy cargo area will give me plenty of rigid attachment points for the frame of the tail extension.

That lower piece of lumber looks like it's designed to fit under the original bumper cover. I take it that allows you to use lots of fasteners and never worry about how to remove it from the car?
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