DIY Network

G-Bar Stabilization System: Trim Rear-Deck Lid From "Tricked Out" episode DTRK-209

	The installed g-bar system with modified carbon-fiber rear deck-lid for a custom fit.
	Media Watch a video on the chassis-stabilizing system.

NOTE: Images on this page may be enlarged for enhanced viewing simply by clicking on them.

In this episode of Tricked Out, host Andrew Totolos installs a G-bar stabilization system on an 1994 Acura Integra. The install is now complete, but the lateral bars interfere with the project car’s carbon-fiber rear deck lid. To complete the project, Andrew trims the carbon fiber deck lid in the project car to fit around the stabilizing system. He uses a rotary tool to complete the custom cut.

Materials and tools used in this episode:

In addition to standard auto-mechanic's tools (wrenches, ratchets, extenders, screwdrivers, nut-drivers, torque wrench, etc.), tools and materials used in this episode include:

Pillar bar
Lateral bar
Harness bar
Harness
G-bar hardware
Shop tools
Scissors
Painter’s tape
Permanent marker
Rotary tools
Safety glasses
Particle mask
Door-sill gasket material
Panel removal tool

Safety Alert: Always wear eye protection and ear protection, and follow proper safety precautions, when working with power tools or pneumatic tools. Also wear eye protection any time you are working underneath a vehicle.

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DIY Difficulty Rating for This Project: We gave this a difficulty rating of 2 on a 5-point intermediate-level scale. Experienced gear-heads should have no problem.

Materials and tools used in this segment

Rotary tool, with cutoff wheel and grindstone
Template
Scissors
Painter’s tape
Safety goggles
Clean particle respirator
Door-sill gasket

Figure A

Trimming the Lid

The owner of this Integra has already installed a carbon-fiber deck lid (figure A), and the new stabilization system interferes with its fit. One option would be to simply leave out the deck lid altogether, but since this owner wants to retain it, it will be necessary to trim it for a custom fit over the stabilizer bars. A template for trimming the deck lid was included with the g-bar installation kit. This makes it simple to cut the deck lid to fit around the new bars.

	Figure B
	Figure C

• Cut out along the lines of the template and place the template in the middle of the deck (figure B). Measure how far back the cut will need to be. Add tape to the deck wide enough to cover all the areas to be cut away.

• Measure the deck to find the center point, and line up the mark on the template with it (figure C).

• Secure the template with tape.

• Trace the outline onto the tape.

• If you're simply cutting a factory deck-lid, you can probably make the necessary cuts using a jig saw. Carbon-fiber is tougher and could get marred by a jig saw. To cut through it, we used a rotary tool.

  Important Safety Alert: As is the case with fiberglass, cutting carbon-fiber produces particulate matter that can be harmful and dangerous. Take proper safety precautions to protect yourself from the particles being inhaled or coming into contact with your eyes or skin. Wear safety goggles and a clean particle respirator, and wear a long-sleeve shirt to protect your skin.
  

  	Figure D
  	Figure E
  	Figure F
  	Figure G

• Remove the paper template.

• Make sure the part is on a solid surface and begin to cut using a cutoff wheel and a rotary tool (figure D).

• Slowly and carefully work your way through the material. Use light pressure to avoid binding the blade and scuffing the part.

• Continue cutting until you get to the curve and start working on the other side.

• Once the second side is to the curve in the design, stop and cut at a 90-degree angle between the two previous cuts.

• Once you've cut through, remove the excess.

• For shaping the curve, change over to a grinding stone. Start grinding in the middle and work your way out (figure E).

• Slowly grind away the deck until you get the exact shape you need.
  
  
• Once both sides are complete, remove the tape (figure F) and wipe the panel down with a damp cloth.

• Slide door gasket material in and around the rough edges of the cut, and trim away the excess gasket material for a professional look.

  You're now ready to place the deck lid in position for the finishing touch on this project (figure G).
  

G-Bar system $500
Harness bar $460
Racing harness $320
Particle mask $5
Cut-off wheels $4
Door trim $5

Total = $1394

Important: Included in this summary are the steps in this automotive procedure as shown in the episode. These steps are general guidelines that are applicable to most vehicles. With any particular vehicle, there may be procedures, specifications, settings, tolerances, components, etc. that are specific to that vehicle. There are also variations according to the type and brand of upgrade-kit you select. Always consult your vehicle's service manual when undertaking significant automotive repairs, and read and follow the manufacturer's directions and precautions that come with your kit or replacement parts.

RESOURCES :

Special Resources for Tricked Out episode 209

Lokar Motorsports
Knoxville, TN
www.lokarmotorsports.com

Racing Innovations
Knoxville, TN
www.RacingInnovations.com

Topshop Co.
Mitchell, SD
www.topshopheadliners.com

Sport Compact Bolt-On Performance Guide: Import Cars (Sport Compact Bolt-On Performance Guides)
Author: Joe Pettitt
Order this book from Amazon.com.
Voyageur Press (October 2000)
ISBN: 1884089526

Honda & Acura Performance Handbook (Performance Handbooks)
Author: Mike Ancas
Order this title from Amazon.com.
June, 1999
Publisher: Motorbooks International
ISBN: 0760306699

Honda/Acura Engine Performance: How to Modify D, B and H Series Honda/Acura Engines for Street and Drag Racing Performance
Author: Mike Kojima
Order this title from Amazon.com.
April 2002
Publisher: HP Books
ISBN: 155788384X

Honda/Acura Performance Handbook: High Performance Modifications for Street and Drag Racing Applications
by the editors of Sport Compact Car Magazine
Order this title from Amazon.com.
November 1999
Publisher: HP Books
ISBN: 1557883246

GUESTS :

Kevin Ford
Lokar Motorsports
Knoxville, TN
Web site: www.lokarmotorsports.com