The basic design that's been discussed here is pretty much what I did with my 60. Here are some pics of my setup. One of the first projects I attempted after I got my 60 about a year and a half ago. Came out pretty decent and gave me a lot ideas of how to approach the project when I eventually redo it.
I started by gutting the interior.
I should also note that I live in a small apartment, no garage, no driveway, no workshop. So between working in the street and in my kitchen, I think this came out alright.
I laid down some sound dampener (Quiet Crap) and cheap indoor/outdoor carpeting from home depot that I used to replace both the original cargo area carpet as well as line the cargo box.
A few beers makes the process go much more smoothly...
I threw it in the back of the truck and put very low profile rubber feet on the bottom to keep it about a half-inch off the floor. When its empty I can literally pull it out in 2 seconds, but otherwise it fits really snug and never shakes or moves around. I think this was pure luck as I was doing all the cutting with a circular saw and my lines are certainly not straight.
I just used a couple L brackets on each side to support the removable side panels, along with a small piece of 2x4 that I secured to the quarter panels. Not very professional, but it gets the job done.
When I fold the rear seat down, I just slide this sleeper panel into place and screw those two lengths of pipe. I saw that setup somewhere here on MUD and copied it - alas I cannot remember who I stole it from, my apologies for lack of proper citation. I like to give credit where it's due.
I used quarter-inch plywood for everything. At first I thought it might have been too thin, but it holds my 180lb ass, my much smaller girlfriend and the dog no problem.
So far so good with it. Multiple camping and wheeling trips up in the Sierras and a two week venture through Baja. Just enough room for a 6' guy to stretch out and the drawers underneath hold 4 gas cans nicely.
