I know they don't cost all that much! And expended effort required, means you should really just buy one. However, postage to Sweden was around the same price as the completed board (total 65 quid).
There is a guide with templates kicking around here. I used it as reference but didnt follow the templates at all. Well i did at first using card board, but fro whatever reason, they didnt really fit/work with my car. In the template they suggest using quit think MDF 10 mm I think. I went to buy this but couldnt find it in a manageable and transportable size. I also figured it would weigh too much once completed. So I settled for some "fibre board" the stuff you line the bottom of drawers and the back of wardrobes with. It was pretty thin maybe 5mm - but light!
BEFORE

I made some card board templates and then transferred them to the board. Yes that is blood in the corner.

Patterns all laid out, I added a vertical piece to the floor to keep it all neat. I also had to cut an arch in the back section to accommodate the spare wheel.

Some speaker carpet - cheep as chips, easy to use and really forgiving, when you male mistakes.


All covered (dog looks amused)
