I am facing a conceptually simple woodworking problem but a sensible
method eludes me...
I bought a Toyota Sienna minivan. To my surprise, they do not make
available a cargo barrier that will hold luggage in the rear of the
van in the event of an accident. So, in the event of a crash, I may be
protected by my airbag, until I am crushed from behind by my luggage
flying at me at the closing speed of the crash...
In any case, I want to make some sort of barrier.
Conceptually, here's what I want to do:
I will put the van through my bandsaw cross wise just in front of the
rear luggage area. Then, I will trace the interior contour onto 1"
plywood. Next, I will cut the ply so that it is an easy slipfit into
the contour. I will then bandsaw out the interior of the plywood
leaving a form fit "frame" of about 3". Because there are thick
structural members in the roof line at that point, the wooden frame
could not force itself past that point of the van. Inside that frame,
I will install nylon mesh to make my luggage barrier. Obviously, I
could pop the entire thing out of the van when I wanted to...
As I said, "simple concept."
But how do I do that sort of thing in fact? Were the contour
dimensions just a few inches, I could use the sort of tool that one
uses to copy moldings etc. but this thing is many feet, and for now, I
can't think of a way to "copy" the interior contour of the van to the
plywood, or to a drawing.
How should I approach this?
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