FJ62 DIY Cargo Box

[Dozer18]

Got it nearly finished after Matt and I worked on it for about six hours today. Got the middle drawer finished, including removable dividers, handle, and key lock.

Installed the Boos Block (cutting board) on push-to-open slides under the Camp Kitchen Drawer, and installed the hidden tool/parts/etc drawer behind it. That drawer is also on push-to-open slides and opens into the cab through a hole on the back of the box; it's only accessible with the back seat down.

 

[Dozer18]

Here's a look at the mostly-completed box:

Still need to put in the smaller drawers that will go under the stove platform and install a few more pieces of hardware. I plan on putting up some tie-down points and still need to finish the design of the extendable sleeping platform. We bolted down the back end of the box into the existing points in the floor; I'm going to try to get the front end (closest to the tailgate) bolted down but I don't know how well the holes we bored lined up.

Oh, I forgot to take a pic but I laid down Dynamat Extreme on the entire cargo floor and wheel wells before putting this back in.

 

[Skniper]

Still looking forward to seeing the fold out sleep deck extension. Nice work. Keep us posted.

 

[Rob Faucett]

How the **** did you get the base in?! My prototype requires removing side panels and lotsa swearing!

 

[Dozer18]

How the **** did you get the base in?! My prototype requires removing side panels and lotsa swearing!

So, when we started we cut the base to the specs in the plans I posted earlier. Early on, it fit into the back by tilting it at a large angle and inserting it in from upper left corner to bottom right corner (the "hypotenuse"). It was a two-man job from the beginning to get it in and out. As it got bigger, heavier, and more cumbersome, something had to give. @Skinper recommended trimming the sides, so I just lopped off the "wing" on the right side (looking at it from the back) and put a piano hinge on it. My friend Matt inserted some rare earth magnets in each piece so it stays up when folded up. With that piece folded up, it goes straight in to the wheelwells, then someone has to lift up from inside the cab and you slide it to the drivers side. Sounds complex, but with that piece cut off and hinged it is MUCH, MUCH easier to put in/take out. Pics below of the wing:

 

[Dozer18]

Got a few more details finished today. Completed the kitchen drawers, putting in liners and a magnetic knife block in one of the drawers. Working on a paracord drawer pull for each since there is only a half-inch of clearance inside the box for the drawer pulls.

Added some hardware to open the big drawers. We installed the slides so that you pull up on the lock levers to open (rather than push down); these little pulls give nice leverage when putting your thumbs on them while pulling up on the levers.

Got some d-ring tie downs coming tomorrow and a bungee-type cargo net. Not much left to do to call it finished...

 

[Dozer18]

Not much left to do to call it finished...

Except for the sleeping platform, @Skniper... I'm still fine-tuning that one but I'm close.

 

[Rob Faucett]

My current strategy is to put in a (semi-perm) 1/2 pre-finished 7-ply "base." Will have mounting t-nuts for attaching the drawer box and Versatie rails. Could get complicated.

Thanks for all your help!

 

[Dozer18]

If I could do it again, I would definitely get nice pre-finished birch for the entire shell and base. I went with unfiinished because I had a few different ideas of how it would be covered (carpet, LineX, etc) but I should've just spent the extra $20. I would still use 3/4 for the base and shell just for strength and durability, especially since it will do double duty as a sleeping platform. The extra weight is nominal.

 

[Rob Faucett]

I never know if it's better to start a new thread or keep similar info together. I'm inclined to post my progress here but don't want to hijack your thread. Do you care?

 

[Dozer18]

I never know if it's better to start a new thread or keep similar info together. I'm inclined to post my progress here but don't want to hijack your thread. Do you care?

I don't mind. Just extra resources for others, and design ideas for me!

 

[Rob Faucett]

I'm going all @kevinmrowland. Started with semi-permanent single piece bottom ( nearly impossible to get in) that will be bolted to the truck through floor. The bottom will also have some Versatie Track for securing the Sceptre and fridge plus other gear. Will have t-nuts pointing up for attached the drawer box. The narrow side where the stove lives will have detachable legs so it can be used free standing away from the truck. Current state of affairs . . . unglued.

 

[Dozer18]

My box isn't 100% complete, but here are a few pics from this weekend's shakedown in Shenandoah:

Still a few things to sort but I'm getting there. Mostly just figuring out some details on where things will go, and that will take a few trips to get the way I want. I installed some nice heavy-duty D-rings on the sides and a perfect cargo net over the top, along with a bungee cords for tie-downs. Would like to put in a Selec-trac on both sides in the future. I'll post a pic of the cargo net setup tomorrow.

 

[Rob Faucett]

Looks great!

 

[GLTHFJ60]

Looks awesome man!! Similar to my latest revision but honestly I think you executed better than I did.

I'd like to recommend boiled linseed oil as a finish. Love that smell

 

[Dozer18]

Looks awesome man!! Similar to my latest revision but honestly I think you executed better than I did.

I'd like to recommend boiled linseed oil as a finish. Love that smell

Thanks much! I don't know about better execution; just took in a lot of things I've seen and liked - including yours - and tried to make something that fit my needs. A few things I'd do different, but it was a lot of fun for me and my buddy to make!

Going to put a new top on it next week with 3/4" finished birch and glue & screw it down. Still trying to figure out how I'm going to finish it. Carpet, LineX, stain, etc...

 

[Kaasdief]

Very nice, well done!

 

[Skniper]

Thanks much! I don't know about better execution; just took in a lot of things I've seen and liked - including yours - and tried to make something that fit my needs. A few things I'd do different, but it was a lot of fun for me and my buddy to make!

Going to put a new top on it next week with 3/4" finished birch and glue & screw it down. Still trying to figure out how I'm going to finish it. Carpet, LineX, stain, etc...

If you are inclined to paint it, Rustoleum used to make (maybe still do) a basic utility paint in various colors. I used it for a bunch of different projects. Water based, low gloss hard finish, no odor, easy to clean surface.
I like paint because it will help seal out the odor of raw plywood in such an enclosed space.
LineX or similar may be too rough.
.....$0.02

 

[Doc Bones]

Wow, I wish you were my neighbor. That is a great setup!

 

[jmcclusk]

Very nice, you've inspired me to make one!