The Ford Barn

mcgarrett · 01-11-2024, 11:03 AM

I have a '40 2 dr. sedan and made my own last year using 1/8" masonite from Home Depot but you might be better off with a heavy poster board material or ABS plastic sheet. I would recommend using large pieces of thin 2 ply cardboard since you will have to make some severe folds/bends to fit the profile of the inside of the trunk wall, trimming as you go. It took a few hours of patient trial fitting and cutting until I finally got the overall shape right. The right side was fairly straight-forward, but as you would expect, I had to do some extra trimming and fitting on the left side to clear the trunk lid support bracket. The 1/8" masonite doesn't have the flexibility to bend too freely, so I cut it undersize just enough to help it pop into place with a little persuasion. It was a tedious process but I'm happy with the results.

01-11-2024, 11:03 AM	#7
mcgarrett Senior Member Join Date: Dec 2013 Location: Corsicana, Texas Posts: 1,551	Re: 1940 Ford Deluxe Trunk Cardboard Panels I have a '40 2 dr. sedan and made my own last year using 1/8" masonite from Home Depot but you might be better off with a heavy poster board material or ABS plastic sheet. I would recommend using large pieces of thin 2 ply cardboard since you will have to make some severe folds/bends to fit the profile of the inside of the trunk wall, trimming as you go. It took a few hours of patient trial fitting and cutting until I finally got the overall shape right. The right side was fairly straight-forward, but as you would expect, I had to do some extra trimming and fitting on the left side to clear the trunk lid support bracket. The 1/8" masonite doesn't have the flexibility to bend too freely, so I cut it undersize just enough to help it pop into place with a little persuasion. It was a tedious process but I'm happy with the results.