Homemade Rear Cargo Storage Solution

[mattmainster]

For weeks, I've been brainstorming, sketching, designing and using Google Sketchup to come up with the most practical rear cargo setup for my rig.
Finally, I came up with a design and made it come to life.

Some of my requirements for the setup were:

• Space for ARB Fridge/Freezer to mount and still be accessible
• Drawer large enough to hold tool kit, recovery straps, hi-ift base, shackles, C02 tank fittings/hose etc...
• Cover only the rear cargo area without having to remove back seats.
• Easy to remove & install on my own.
• Leave access to the compartment where the bottle jack is and where the diff breather will be
• Keep the inverter usable.
• Lockable drawer
• Space to mount my 10lb C02 Tank

Just a few notes...

Everything is made from 3/4" plywood. The drawer slides are rated for 100lbs fully extended. The unit is bolted to the floor in 2 locations where the d-rings were previously, and is held don in the rear by a turnbuckle connected to one of the d-rings in the back.

I have a flat-head extension cord that fits in the inverter outlet that is long enough to be run anywhere in the vehicle.

The carpet was stuck down with contact cement and then stapled.

If I didn't have such a hard time finding the right carpet, the whole thing could have been done in about 6 or 7 hours and the whole thing cost me just under $100.

There are still a few finishing touches to be done:

• I will be adding a lock to the drawer.
• The existing handle will be swapped for a black, flush-mount handle.
• Two 12V sockets will be flush-mounted to the box..one will be used for the fridge..
• Tie down points or d-rings will be added to hold the fridge down even though it fits very snug
• I'm sure I'm forgetting something....



Anyways, here are some pictures. If you have questions, ask away!

Just getting started...
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/IMG_0498.jpg

Basic frame
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/IMG_0502.jpg

Test Fit
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/IMG_0503.jpg

Finished
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/Library-8817.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/Library-8819.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/Library-8822.jpg

[Crikeymike]

Looks good. I think because you've kept it nice and simple, the weight probably isn't much of an issue, and having the fridge nice and low is good.

I should also bring up a "cheap" drawer slide method. TruckVault uses small embedded wheels into the base under the drawer, and the rear upper section of the drawer as well to counter the weight when the drawer is out. It's like a caster that's half embedded into the 3/4" plywood, with just the caster sticking out, so the drawer slides in and out on small casters instead of roller slides like you used. I know what you used would be smoother and straighter, but for those who are making bigger and heavier drawers, the caster idea definitely works. http://www.truckvault.com/Support/Info/Care/Default.asp

http://www.truckvault.com/Images/parts/rollers.jpg

[mattmainster]

Looks good. I think because you've kept it nice and simple, the weight probably isn't much of an issue, and having the fridge nice and low is good.

I should also bring up a "cheap" drawer slide method. TruckVault uses small embedded wheels into the base under the drawer, and the rear upper section of the drawer as well to counter the weight when the drawer is out. It's like a caster that's half embedded into the 3/4" plywood, with just the caster sticking out, so the drawer slides in and out on small casters instead of roller slides like you used. I know what you used would be smoother and straighter, but for those who are making bigger and heavier drawers, the caster idea definitely works. http://www.truckvault.com/Support/Info/Care/Default.asp

http://www.truckvault.com/Images/parts/rollers.jpg


Thanks! The whole thing, even with the drawer in, cn be installed and removed by myself. My guess is that it weighs 50lbs or so....I'll try and weigh it tonight.

I like the idea of those casters, but it looks like something that would have to be factored in when drawing your original plans. The slides I'm using are rated at 100 lbs. I can't imagine having anything that weighs that much in the drawer.

[Bighead]

Looks good. How are you securing it to the floor?

[tdesanto]

Looking good!

Maybe some lash-down points installed on top for other gear?

Like this:24446

[mattmainster]

Looks good. How are you securing it to the floor?

It's bolted down through the floor where the factory d-rings used to be, and held down in the rear by a turnbuckle.

[mattmainster]

Looking good!

Maybe some lash-down points installed on top for other gear?

Like this:24446


I have 4 of those, ready to be screwed into it. Thanks!

[Crikeymike]

It's bolted down through the floor where the factory d-rings used to be, and held down in the rear by a turnbuckle.

Inside of the drawer cavity, or to the side of the drawer? Is it awkward to get it installed/removed?

I want to do something similar in my sidekick, but I'll have to figure up some mounts since there's no factory holes or threaded holes to work with.

[mattmainster]

Inside of the drawer cavity, or to the side of the drawer? Is it awkward to get it installed/removed?

I want to do something similar in my sidekick, but I'll have to figure up some mounts since there's no factory holes or threaded holes to work with.

One bolt is underneath where the drawer sits, and the other is on the flat platform on the left where the fridge sits. To access the one under the drawer, the drawer has to be removed (very easy to do).

[mattmainster]

Got to use the drawer setup this weekend in Anza Borrego...here are a couple more pictures:

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-051.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-053.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-054.jpg

[JamesDowning]

Great work! I need to get myself a fridge, though the cooler works for now I guess.

I had actually just built my own version of a rear cargo drawer:

http://www.thedownings.us/images/tb/update1/rca11.jpg

As is, I have about 80 lbs in the drawer. I can't see storing over 100 lbs ever.

In case you haven't thought about this, I used retaining pins (made for sliding doors) on the side of the box that engage detent holes in the drawer (to hold the drawer in or out). One is visible in the pic below.

I also wanted to retain use of my under-deck storage tub, so I had to build a small hatch.

http://www.thedownings.us/images/tb/update1/rca14.jpg

I left a small cavity between the seat and the drawer. I will be mounting an inverter, a compressor, and a small deep cycle battery back there.

Cheers! http://hfboards.com/images/smilies/cheers.gif

[Colorado Ron]

Got to use the drawer setup this weekend in Anza Borrego...here are a couple more pictures:

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-051.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-053.jpg

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/09-054.jpg


I dont see your latest copy of Overland Journal anywhere? Isnt that required? I thought I read that somewhere.LOL:shakin:

[Colorado Ron]

.


http://www.thedownings.us/images/tb/update1/rca11.jpg




Whats the orange storage? Looks like stackable units of some sort.

[j_nigrelli]

looks like this but different:

http://www.cpofestool.com/categories/systainer_organizer_systems.html

[JamesDowning]

http://www.cpofestool.com/images/product/festool/large/445433.jpg

Yep very similar to the festool version.

http://www.bti.de/english/static/shortcuts/images/systra1.jpg

http://www.bti.de/english/static/shortcuts/systra.asp

I'm a power-tool engineer, and I see all sorts of cases cross my desk or the halls of the building. We rebrand some of our tools for other companies, including BTI. Their Systra Modul was perfect to make a compact and easy to carry emergency kit. So I yoinked a few of the cases for personal use. I carry military food rations (MREs), a bit of water, a medical kit (with IV), and survival gear in those 3 cases.

[Honu]

looks good :) only thought make sure if you bury your rear end or cant get access to the back you can still get to some recovery gear that might be needed ?

but fun to see another FJ with some cool stuff great job ;)

[mattmainster]

Great work! I need to get myself a fridge, though the cooler works for now I guess.

I had actually just built my own version of a rear cargo drawer:

http://www.thedownings.us/images/tb/update1/rca11.jpg

As is, I have about 80 lbs in the drawer. I can't see storing over 100 lbs ever.

In case you haven't thought about this, I used retaining pins (made for sliding doors) on the side of the box that engage detent holes in the drawer (to hold the drawer in or out). One is visible in the pic below.

I also wanted to retain use of my under-deck storage tub, so I had to build a small hatch.

http://www.thedownings.us/images/tb/update1/rca14.jpg

I left a small cavity between the seat and the drawer. I will be mounting an inverter, a compressor, and a small deep cycle battery back there.

Cheers! http://hfboards.com/images/smilies/cheers.gif


I really like the retaining pin idea. I think that's what I may end up doing. Thanks!

[teotwaki]

Hi Matt! Nice project and great write up!

What brand cargo net is that holding everything back?
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/IMG_0498.jpg

[mattmainster]

Hi Matt! Nice project and great write up!

What brand cargo net is that holding everything back?
http://i27.photobucket.com/albums/c187/matt_main/The%20Box/IMG_0498.jpg

Thanks! That's the FJ Cargo Barrier Net made by the great guys at www.offroadconcepts.net

[mattmainster]

Update...

I haven't gotten around to switching the handle yet, but did add a small latch to keep the drawer shut if I were to open it on an incline.

I also added one small, but important finishing touch. Can you spot it? :)

:beer:

http://i27.photobucket.com/albums/c187/matt_main/The%20Box/photo.jpg

[WJinTRSC]

Nice location for the bottle opener. Very handy.