Ok, with the shelf panel straight and test fitted, it was time to make the lower panel. Since the original one was destroyed by the guys who attempted to "restore" the interior, I basically had to make a pattern and start with a new interior panelboard. After making a cardboard mock up, I cut the panel and creased it using my pan brake - worked great:
After a few attempted test fits, some more trimming, and a final sanding, it fit pretty well:
The rear metal tab was ripped off the original panel, so, I used some 18ga galvanized steel and made a new one. Then figured out where it needed to go and mounted it to the panel with pop rivets:
Now the fun begins...time to cut some leather and upholstery foam. I used 1/8" high density foam to support the leather, soften the panel and give it some padding. A commercial grade spray adhesive is the only thing to use as it is a high temp glue that won't loosen or give up in a hot car in the summer. However, you get one chance to place it because it does not come off w/o destroying the leather and the foam! Here is the initial set of the black leather on the rear tray panel:
And after finishing the edge:
and clamping the leather at the relief for the mounting surface for the lower panel:
Taking a break, I then installed the new carpet on the backs of the rear seats:
With that done, time to do the lower panel. That was going to be a bit more complicated. Out of my pic allowance so...that is for the next post.