Toyota 78 pop up roof (1 Viewer)

[renago]

Hi Paul

at the end I have almost decided to go the old way , which means making boxes of 1,5 mm aluminium sheet .
folded , welded and some points riveted .
it's not the most economical way , but surely lightest , very strong , I had some for 14 years , and not a problem .
plus it gives me the maximum usage of internal space , as far as there is no frame .
the front of drawers will be made in HPL 4 mm , still to be decided .
the front of the drawers will most probably made in HPL 4 mm ??? maybe .
the top in marine grade wood , laminated in formica .
this solution will allow me to re utilise my old boxes with some modification ,to fit them to the new lay out .
saving me some €€€.
consequently the research on square tubes and joint system has dropped .
asap I will post some photos .


for you planning HPL is a very good material , 3 mm is more then enough .
I would not go thicker than that , no need .


bye Renago

 

[jchhiminey]

Amazing. Thanks for sharing.

 

[renago]

Thanks.

 

[renago]

just a small update on kg ?
today I have restarted measuring and designing the new interior .
as said previously I will go with aluminium 1,5 mm boxes , custom made .
i have a few left over from before , they are 80 cm long , 48 cm wide , and 50 cm high .
for a total of 11 kg aprox .
I think there isn't any solution lighter then this .
not cheap ,
but I can use the maximum cubic mt viable , with virtually no loss in box volume .
strong , these are 14 years old , with every year trip to rough lands .

 

[renago]

 

[Paulrotterdam]

Hi Paul

at the end I have almost decided to go the old way , which means making boxes of 1,5 mm aluminium sheet .
folded , welded and some points riveted .
it's not the most economical way , but surely lightest , very strong , I had some for 14 years , and not a problem .
plus it gives me the maximum usage of internal space , as far as there is no frame .
the front of drawers will be made in HPL 4 mm , still to be decided .
the front of the drawers will most probably made in HPL 4 mm ??? maybe .
the top in marine grade wood , laminated in formica .
this solution will allow me to re utilise my old boxes with some modification ,to fit them to the new lay out .
saving me some €€€.
consequently the research on square tubes and joint system has dropped .
asap I will post some photos .


for you planning HPL is a very good material , 3 mm is more then enough .
I would not go thicker than that , no need .


bye Renago

Thanks for the tip Renago, i'll stick to 3mm.

Ive made an initial design in this topic, feedback more than welcome

Toyota HZJ75 Troopy interior build

 

[Owyhee Jackass]

Is the inside of the box wide open, or do you have some dividers in there?

 

[renago]

I have 3 boxes like this .
2 wide open
1 divided at 50/50.
The one in the picture has the hatches removable, in case you want to store some big object .
All boxes are lined with thin microfiber fabric , aluminium will become dark and stain objects that rub the surface.

Bye Renago

 

[renago]

Hi Guys
long time with out any post , but there are some reasons ....
aluminium took almost 1 month for delivery , then usual delays .
cut the story short , here is where I stand :
2 existing boxes have been remodelled , cut , welded and riveted to the new scheme.
they look a bit Frankenstein ! but welding lines will not be on the front .so none will see them .
3 brand new taxes have been made .
still al LOT of work ahead .
but I MUST finish for 30 May , as we are leaving for a short holiday in Sardinia .
this will be a good test for our new interior .
here are some pictures .

 

[renago]

 

[Hiace4wd]

Nice!

 

[renago]

Sorry for the double pictures

 

[Owyhee Jackass]

Will you add tabs to the base and bolt to/through the floor? Do you attach to the wall as well?

 

[renago]

I have a wood floor bolted to the car .
The wood floor is 1,5 cm thick .
I generally drill a hole and screw in threaded insert .
Fix the box with 4 - 6 bolts to the floor .
It works fine for me .
The aluminium boxes are not bolted to the wall .
This will allow a certain degree of flex in the vibration and twist of th car .
Preaviosly I had same boxes , but different size for 14 years .
Many trips in North Africa with heavy equipment and bad roads and no roads .
Never a problem .
I keep the box at 2-5 mm from the wall of the car , this will allow also a better thermal insulation.
The food box is also lined with a 3 mm cork panel.
Light and excellent thermal insulator .

More photos will be coming soon .

Bye Renago

 

[renago]

some photos of the endless work in order to re use existing boxes .
in all honesty , I must say , that I saved some money in the re use , but the final job and the time needed was too much .
ok , I can't count my time in €€€ , but still ...

I think that next week I will be able to finish the metal work .
then I have the wood front panel , top , waterhuse , and some other tricks .
endless story

bye Renago

 

[goexplore]

I’b Be interested in hearing the total weight of the cupboards you’ve created.

I’m weighing up (if you excuse the pun) of building between allow tubing/panels, alloy frame and composite cladding or full wooden structures.

I know you’re keen to keep weight down as much as possible, and it’s the same for me. With the roof adding around 150kg to the overall vehicle weight, I’m trying to reduce in other areas, and keep everything as low in the vehicle as possible to bring the centre of gravity down.

 

[renago]

The best way to keep center of gravity low is to put all liquids , fuel and water , UNDER the car .
You will have a big benefit in terms of road /off road handeling .
Can't remember the total weight of pop up roof and bedding , but would estimate approx 100 kg , maybe less .
Made in 3 mm aluminium .
Bed base is in honeycomb panel , very light .
Simple boxes are 11 kg
boes more complex with drawers ecc , will be more heavy but still much lighter then a wood alternative.
Can't say now how much , too far from the end of the job.
Will keep you posted on th end result .

Bye Renago

 

[renago]

slow progress , despite a lot of work .
I need to glue some fabric on the sides and rear of the boxes , in order to stop any eventually rattling or noise .
this should be done tomorrow .
here under you can see , the mock up top cover .
not quite right so far , might have to remake it ....

 

[renago]

this has nothing to do in the interior set up , but I am very pleased with how it came out .
retracted rail for Garmin 276CX ,

 

[renago]