1gen Neon Kammback/Hatch conversion

[NoD~]

So I've been planning to do this for about a year now, just finally getting serious about it. Still not 100% sure how I want to implement it to the final stages, but here's the goal:

-Follow template to improve aerodynamics
-Have full functional rear view, as good as factory
-Fiberglassed to body, make it look less... "duct-taped"
-Fully functional lifting hatch
-Add no weight, possibly reduce it
-Increase insulation properties

So, here is my progress to date.


Used the template to get the general shape, then took off 1" for the top layer of this insulation foam.


Good bracing to keep it strong until fiberglass comes down. Copied the same design 3 times, allowed curve of body to dictate curve of top this way. Connected these with glue/screws to secure them well together.


Marked center and where the 3 braces would go for glue and screws


Glued, Screwed, and threw some weight on it to make sure it holds good form and push on the ends where screws wouldn't work. If you can tell, there is a steep angle on the end to help mold to the body better. Probably shape that a little further still, too.


Back view. That's the glue I used, made for this material.


Here's a close up of the adhesive squishing out the sides. It doesn't dry very fast, but seems to turn into what I can best describe as old chewing gum under a desk.


Here's a shot from inside the cab, drivers seat looking back. I'll be cutting back some and putting in a ~4x x ~4 foot window. This will be a part of the hatch conversion. The rear will also get a window. All similar to a Prius hatch, you could say.

So, that's it thus far. I still need to build the sides and attach them, then get the back together. I think I'll get a layer of fiberglass down on it at this point to keep form and strength, then start cutting and making the hatchback.

The trunk itself will come out, as well as the factory rear window. I'll be using acrylic for better insulating and less weight (plus, easier to work with in this kind of customization!). Still trying to figure out how to do the trunk part... hinges, attachment, seal, even the materials to use (thinking good plywood would be easiest).

[botsapper]

Someone else wanted to do this . Good luck on yours. http://ecomodder.com/forum/217527-post30.html

[Xist]

There is a discussion going on about the MX-3 aerodynamics. If that hatch is just glass, or you find one that is, you could just weld the hinge(s) and add support for the struts.

[MetroMPG]

Subscribed.

[AndrzejM]

Maybe you could fabricate trunk from the same foam material? Is that XPS? If you'll cover that with fiberglass and epoxy it will be very light and strong. It can be hard to embed latch into it though. But you can always use a piece of plywood fiberglassed into it.

[NoD~]

Yeah, extruded polystyrene. Stuff seems easy to work with. I've been using a steak knife for most of my cuts! 2" screws, thrown in by hand with a bit, since it doesn't take much.

I was planning on plywood on the hatch body and the hatch itself to insure strength, as well as a good seal.

I started on the sides today... I now realize that will be the greatest challenge and will require a lot of careful shaping! What have I gotten myself into?!

[mikeyjd]

Looks like you have your work cut out for you. Good luck in your streamlining endeavors.

[Mira]

Originally Posted by NoD~

-Follow template to improve aerodynamics
-Have full functional rear view, as good as factory
-Fiberglassed to body, make it look less... "duct-taped"
-Fully functional lifting hatch
-Add no weight, possibly reduce it

Looking good! It seems like we have a similar approach ^^^

Somehow, I had never thought of a hatch conversion before! Gonna weigh out the factors, maybe it's a good plan for me and Smokey. Good luck with the Neon!

[Xist]

Perhaps you could create a plug of the trunk and fabricate a custom one from that.

[Smurf]

I've been tossing around a similar idea with my Grand Am's trunk.

(Note: I have ZERO experience in any of this, just research and overthinking)

The plan is to build a basic metal rod framework cube on the trunk, probably using the spoiler mounting holes for the rear mounts. Then stack up foam layers on the outside of the box, working towards the rear glass. Do the other side, and the top. Shape it as needed, carve out more material from the inside, fiberglass it all, secure it to the trunk. Or something like that.

Can't wait to see how yours turns out.