John, I have several relatives and friends that live in Dalton, Georgia
the carpet capital of the world.  One of my wife's cousins works in a
place that makes OE and aftermarket carpet kits for vehicles.  I asked
him about how these are made and it is more than just cutting and sewing
the edges.  They make a mock up of the floor of the car and they have
special forms and tools to shape the carpeting into a three-dimensional
shape, instead of just a flat piece of carpet.  So I don't think you are
going to be able to replicate this work in your garage.  The best thing
to do would be for us to find one of these places that will make
aftermarket carpet kits for the van that are not just cut out to the
proper dimensions but also shaped with the tools they have.  If anyone
is interested I could speak to him about this.

--
Thanks,
Ken Wilford
John 3:16
www.vanagain.com
Phone: 856-327-4936
Fax: 856-327-2242

On 2/2/2011 11:36 AM, John C... wrote:
> Curious George here.
>
> I have all of my carpets out of the Van
> and laying on the shop floor.
>
> And I,m wondering how VW formed all of the shapes into the carpets.
> Especially into the front carpet.
>
> Does anyone know how they did that
> or have any general insites into how it's done?
>
> Heat and a form press I'm a guessin' ?
>
> It would be great to be able to emulate what the factory has done.
> I have some silver gray carpet that would be perfect in my Vanagon.
>
> Can we do this at home ???  ;o)
>
> Thanks,
> JC...
>