DIY Network

S2000 Racing Upgrades: Custom-Fit Rear Deck and Harness Replacement Autocross Racing Enhancements, Part 2 of 3 From "Tricked Out" episode DTRK-309

Racing harness components

In this project, Andrew Totolos installs a four-point roll bar, an upgraded racing harness setup and stiffened stabilizer bar on a Honda S2000. Now that Andrew has completed the harness bar installation, he'll trim out the rear deck in the car to fit around the new bars.

Materials and tools used in this second phase of the project:

cardboard
utility knife
tape measure
paint marker
rotary tool
4-point harnesses

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	Figure A
	Figure B

Trimming Rear Deck

• Start with a piece of cardboard, and trace the deck lid outline onto it. Then, cut the excess cardboard off and double-check the fit with the deck lid before taking it to the car (figure A).

• Center the cardboard in the deck lid mounts and push it up against the roll bar supports to begin.

• Then measure the depth from where the front edge of the factory deck lid would meet the next trim panel to the back of the bar. Mark the inner edge of the cut where the tape measure crosses the template. Use your depth measurement to position the rear mark.

• Go to the other side to make a mark for the outside edge of the bar (figure B).
  

  	Figure C
  	Figure D

• Using a utility knife, cut the hole out of the template (figure C) on both sides and check the fit with the bars.

• Lay the templates onto the factory deck lid with a paint marker (figure D).

• After the holes are marked, use a cutoff wheel in a rotary tool to make the cuts on both sides of the deck. Use light pressure and take your time for a professional cut.

• When you're satisfied with the shape and position of the cutouts, clean up the cuts with a little sandpaper to finish up.

• Now that the piece is trimmed out, it's time to replace all of the trim panels.
  

  Figure E

• Carefully align the piece and press it down to pop in the retaining clips.

• Replace the remaining trim panels and panel clips in the reverse order to complete this part of the project (figure E). The next step is to replace the harnesses.

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