I have in the past used steam or hot water to help shrink/stretch carpets 

Dave try alternative thinking carpet will not mould to tunnel, so reshape or remove the tunnel problem solved

I would phone Nick up at rugs for bugs as suggested he has done quite a few buggy sets and is always after business so a bit of technique help may generate him some more work.

I have put them in the recommended suppliers section

I have in the past used steam or hot water to help shrink/stretch carpets 

Well, steam sounded like a good idea - so I dug the steam cleaner out of the garage, and had some absolutely cracking results with it - I have now moulded a one piece carpet for the Buggy and pretty chuffed with the results. I`ll post some pictures up on my build thread as soon as the camera is charged back up.

I have in the past used steam or hot water to help shrink/stretch carpets 

Well, steam sounded like a good idea - so I dug the steam cleaner out of the garage, and had some absolutely cracking results with it - I have now moulded a one piece carpet for the Buggy and pretty chuffed with the results. I`ll post some pictures up on my build thread as soon as the camera is charged back up.

Amazing how u can make carpet stretch/shrink with steam 

Pictures are now here

http://www.beachbuggy.info/index.php/topic,20.msg22876.html#msg22876