Tailgate Storage Box

Tofudebeest · 08-10-07, 10:58 PM

Wish those were mass made...

calphi27 · 08-11-07, 10:25 AM

Quote:

Originally Posted by MyHJ60Sheila

Wish those were mass made...

x2

Anyways can you give us a little part list? Where did you get those latches, hinges, and can you give us the specs on the metal frame surrounding the quarter panels and tailgate?

How is the tailgate holding up? Can you sit on it will all the supports removed? Just to clarify, did you cut out all supports in the quarter panel area?

Thanks in advance and nice work!

[

I vote to add this to the 60s FAQ

Creeker · 08-11-07, 11:54 AM

Very nice work, from conception through execution! Have you thought about adding sound-deadening now that you have such easy access?

srplus · 08-11-07, 12:20 PM

I have been considering doing this with my 60 and have been thinking of expanded PVC sheet (see http://www.sdplastics.com/pvcx.html ) that is used in the sign industry... it comes in all kinds of colors and thicknesses. It is not at structural as Starboard or the like but it would be very functional for doors, etc.

boerboel313 · 08-11-07, 01:11 PM

Tail gate is a good place to put a nice tactical shotgun. SORRY.
Very nice work, I love the idea.

77TLCFJ40 · 08-11-07, 01:52 PM

Great idea.

Fantastic execution!

You should mass produce these.

calphi27 · 08-11-07, 04:58 PM

Quote:

Originally Posted by boerboel313

Tail gate is a good place to put a nice tactical shotgun. SORRY.
Very nice work, I love the idea.

That is a great idea!!! I like it!

kevinmrowland · 08-11-07, 05:55 PM

Thanks everybody, glad you like it.

Quote:

Originally Posted by calphi27

Anyways can you give us a little part list? Where did you get those latches, hinges, and can you give us the specs on the metal frame surrounding the quarter panels and tailgate?

The hardware is all from Mcmaster-Carr, pull latches and stainless piano hinge. I welded a flange on the hinge so that I could screw (in the case of the 1/4s) and through bolt (in the case of the tailgate) through the panel rather than into the edge. 1/2" plywood does not like to hold fasteners in it's 1/2" dimension. All the bolts use the existing mounting holes and stainless hardware.

Quote:

Originally Posted by calphi27

How is the tailgate holding up? Can you sit on it will all the supports removed? Just to clarify, did you cut out all supports in the quarter panel area?

The OE tailgate was all caved in before this all started, I used the subsequent boxes to actually pull the tailgate back into shape. The frame is made from 2 pieces of angle iron, the two short sides and one edge are bent from one piece and a second piece is welded in to connect the legs. Plenty strong enough to sit on, in fact my test for them consists of dropping my 33" spare tire on them from the roof (I like things strong)

Yep. I cut all the vertical supports out of the 1/4s, the new panels are 13ga. steel with a lip welded to the inside of the opening for rigidity, plenty strong as well.

Quote:

Originally Posted by Creeker

Very nice work, from conception through execution! Have you thought about adding sound-deadening now that you have such easy access?

I would, except I am too cheap to waste my $ on sound deadening for a rusty body, I used the cheap stuff inside the tailgate to clean it up and I will do the same for the 1/4s as soon as I get around to chopping them (welding and sound proofing don't mix very well

)

Quote:

Originally Posted by srplus

I have been considering doing this with my 60 and have been thinking of expanded PVC sheet (see http://www.sdplastics.com/pvcx.html ) that is used in the sign industry... it comes in all kinds of colors and thicknesses. It is not at structural as Starboard or the like but it would be very functional for doors, etc.

Yup, nice stuff, I looked at the Nidacore as well, but once again the strength-weight-and especialy-cost came into play again.

Quote:

Originally Posted by 77TLCFJ40

You should mass produce these.

I could always make more but you all know how cheap we are.

It takes me a least a few hours to make, two latches are $26, the stainless hinge (which I then have to modify) is like $20, plywood is not cheap these days and neither is steel.

sirenmoses · 08-11-07, 06:02 PM

Quote:

Originally Posted by kevinmrowland

I could always make more but you all know how cheap we are.

It takes me a least a few hours to make, two latches are $26, the stainless hinge (which I then have to modify) is like $20, plywood is not cheap these days and neither is steel.

Is there a group buy coming on???

I'll send stickers w/my $$ since it looks like you've added to your collection.

Very nice stuff!

calphi27 · 08-11-07, 07:31 PM

Well there are too many here that be interested. Looks like you have no choice but to quit your job and open shop just like 2badfjs. NICE WORK!!!

lovetoski · 08-11-07, 08:23 PM

Since I can't weld...the "hard" part is making the metal rim piece. The rest I can do.

GAS-A-LOT! · 08-12-07, 02:11 AM

SOOOOO... How much for the tail gate kit with shipping?

I mean, It sounds like you should calculate the cost and add your labore fee and produce a couple to see how it sells.... Hell, I'll buy one...

rmcquet · 08-12-07, 07:26 AM

x2 for me, too.
I'd be all over the tailgate storage upgrade.
Add me to the group buy if it gets that far!

kevinmrowland · 08-12-07, 09:14 AM

Well, alright, I'm thinking about it...........

srplus · 08-12-07, 09:21 AM

Quote:

Originally Posted by kevinmrowland

Well, alright, I'm thinking about it...........

A couple of things... you might want to check out that expanded PVC since it might end up less expensive than the plywood you are using and a lot of sign shops have CNC routers that are computerized and can cut the panels quickly with all of the holes for hardware and insets for hinges so that things will be flush. This will save you a lot of labor time and since it can be jobbed out you will not have to have lots of inventory laying around.

Also, aluminum piano hinges would most likely work just as well and would cost less money without making the product less functional or cheesy.

calphi27 · 08-12-07, 09:35 AM

Read up on post 38. They are piano hinges.

Are the 1/4s rivetted to the factory holes?

Sherpa 60 · 08-12-07, 10:03 AM

Nice. Thought many times about taking better advantage of the quarter panels, but never the tailgate. Good stuff.

Really like the latch hardware. I would be interested in knowing whose it is and where you got it.

As an aside, I found the left rear quarter was a good place to mount my ARB compressor (early 60 w/no window washing tank). Less dirt and dust and I now have a power point at the rear of the truck (fridge) and a quick disconnect for air which is accessed thru the old fluid filling cap.

Sherpa 60 · 08-12-07, 10:05 AM

Gotta read more carefully...got the hardware manufacturer!

GAS-A-LOT! · 08-12-07, 03:13 PM

yeeeehaawwllll..... ride em tailgaters....!!!

I mean .... yeah! looks like we might get a group buy.... Or... We just found/created another vendor here on Mud! Yeah!!

Sweetdoo · 08-12-07, 03:54 PM

NICE WORK. That looks great, and is obviously very functional too. Beats my rubbermaid tote sliding around in the back.

Count me in for a set of 1/4s and tailgate if you decide to mass produce!

CardinalFJ60 · 08-12-07, 04:03 PM

Great work Kevin. If you decide to move forward on making the tailgate boxes - I'm 100% in. I've been monkey'in around with an all-wood version; basically it sucked. and that's an understatement.

I really like it. good stuff.

kevinmrowland · 08-12-07, 05:27 PM

Quote:

Originally Posted by srplus

A couple of things... you might want to check out that expanded PVC since it might end up less expensive than the plywood you are using and a lot of sign shops have CNC routers that are computerized and can cut the panels quickly with all of the holes for hardware and insets for hinges so that things will be flush. This will save you a lot of labor time and since it can be jobbed out you will not have to have lots of inventory laying around.

Also, aluminum piano hinges would most likely work just as well and would cost less money without making the product less functional or cheesy.

Yeah, when I looked at that stuff originally it didn't look like it had the same kind of strength as ply. I will see if they will send me a sample to check out. It is also 2x as much $ for the same dimension (a smaller dimension could work) It has the benefit of not needing finish, but the downside of not being able to re-finish it. And on the 1/4s, I actually really like the varnished wood. Everything is a compromise.

We use a local laser guy to cut things for us at the shop, I often tack some stuff of my own on the orders as well. He cut the 1/4 panels for me, and even though I did the ply myself, I already have the CAD files for them and the laser has no trouble cutting 1/2 ply. I can not say enough about laser cutting, saves me loads of time.

Aluminum hinges are cheaper, but since I need to weld a 90 degree bolt flange onto the plywood side of the hinge (to facilitate screwing into the face of the ply rather than the edge) the stainless is much stronger and easier to weld.

Quote:

Originally Posted by calphi27

Read up on post 38. They are piano hinges.

Are the 1/4s rivetted to the factory holes?

I think srplus is just suggesting to use aluminum over stainless to save some money.

Both the tailgate and the 1/4s use the same stainless flat head hardware right into the OE mount holes.

calphi27 · 08-13-07, 01:00 AM

Would you mind posting the part numbers for the piano hinges? There was a large variety of sizes, and I wasn't sure what worked. I found the latches though. Thanks again.

vipergrhd · 08-13-07, 05:01 AM

hey that is really cool,it is a great idea.excellent workmanship also.

Tofudebeest · 08-13-07, 05:40 AM

Price these at $250 for the tail gate and $300 for both cargo panels and you'll quickly lose all your free time.

kevinmrowland · 08-13-07, 11:37 AM

Lets keep this tech, I am looking into making some more, at this point I am planning to make another one and see how it goes.
MyHJ60Sheila, the #s you posted are realistic, I hope to be a bit under, but too soon to tell.
Let me see what I can do for everyone and see how it works, but lets avoid posting prices and orders in the tech section.
I will keep updating this thread with tech stuff, and when the time comes, start another thread in the appropriate section.

calphi27, I will check on the Piano hinges for ya, I order a lot of hinges and I am not sure which ones I used.

All the interest is very exciting, would be fun to make some cruiser parts.

g-man · 08-13-07, 05:26 PM

Are you good at welding aluminum? I think aluminum angle in the tailgate would be lighter but strong enough and rust free. Are the 1/4 panel doors just a frame and a door? or is there a shelf built into the frame to set stuff on? I cant tell by the pic. This really is a great project and would sell at the right price!

Dynosoar · 08-13-07, 06:58 PM

Hi Kevin,

Could you possibly post a pick (similar to the on in post #23) with the tailgate box empty. This will help me visualize hoe it was made.

Thanks

Dynosoar

Zako · 08-14-07, 12:57 AM

Mate, you got any more pics of the mattress setup as this is EXACTLY what I'm planning on doing to my FJ60.

Any info would be greatly appreciated.

Kind Regards,

Zako

CaliCruiser · 08-14-07, 11:44 AM

Dude you are the king of mods! As many have said before, excellent work. I would be interested in the tailgate box if they become available.

Dylan