Carman's Auto Upholstery in Slacks Creek approached me to develop a digital design for custom boot interior trim panels for the VK Commodore.
The project involved converting existing MDF template panels into accurate CAD files that could be supplied to a CNC machining company for repeatable production. This would allow Carman's to offer the same custom trim package to other VK Commodore owners without having to manually template and manufacture each set of panels from scratch.
The finished panels were wrapped in blue vinyl to complement the factory interior, creating an OEM+ appearance that retains the character of
the original Commodore while adding a more refined, custom finish.
The existing MDF panels provided the starting point for the digital design. I 3D scanned these physical templates and used them as reference to develop accurate CAD models of the front and side boot lining panels.
The aim was to retain the original panel shapes and fitment while converting them into digital files suitable for CNC routing. This required translating the existing templates into clean, manufacturable geometry that could be reproduced consistently for future customers.
With the main panels digitised, Carman's would have a repeatable design that could be sent directly to a CNC company for production,
reducing the need for manual templating and allowing the same trim package to be supplied to other VK Commodore owners.
The rear of the boot presented a different challenge. After scanning the rear of the interior boot area, I designed a separate rear lining panel in CAD to follow the curvature of the boot's rear bodywork and provide a clean cover over the tail light access areas.
The panel was designed for 3D printing in ABS plastic, allowing the geometry to follow the vehicle's shape while incorporating mounting features for a magnetic attachment system.
Using magnets allows the panel to be removed when access to the tail lights is required, without the need for visible fasteners or permanent modifications to the vehicle.
The design also allows the panel to be wrapped in vinyl to match the surrounding MDF panels, creating a consistent finish across the entire boot interior.
With the MDF panels converted into CAD and the rear panel developed as a separate 3D printed component, the project established a digital foundation for repeatable production.
The CNC-ready files allow the main panels to be manufactured consistently, while the custom rear panel can be reproduced using additive manufacturing.
This approach combines conventional trim materials with digital design and fabrication methods, providing a practical way to develop custom interior components for a classic vehicle.
The completed boot trim gives the VK Commodore a clean, OEM+ interior appearance, with blue vinyl upholstery tying the custom panels into the existing interior.
For Carman's Auto Upholstery, the project also provides a way to turn a one-off custom trim job into a repeatable product. The digital panel designs can be supplied to a CNC company for production, allowing the same package to be manufactured for future customers with the same vehicle.
The project demonstrates how existing physical templates can be converted into production-ready CAD files, while combining CNC machining and 3D printing to develop custom automotive interior components.