i made some good progress this weekend on a version 2.0 of my rear storage/fridge-slide/sleep platform.
- this was my previous setup...
- and some small tweaks i made a little later...
the new version will have a permanent drawer. i've always preferred just using multiple Pelican style cases before, but i've found certain tools & supplies stay in my rig. this meant that to sleep in there, i always had to pull out 2 of my heaviest cases and set them outside at night.
the new sleep platform will be at the same height as the drawer case and should be faster/simpler to deploy.
here's the start of it all:
i could have re-used some of the existing stuff like the base and fridge slide, but i've decided to just start over and incorporate several improvements.
i'm using 1/2" plywood for everything instead of King Starboard/StarLite. i really liked working with the plastic, but it's just not as rigid as the same thickness plywood and was also slightly heavier.
here's the bottom of the new platform. the 1/2" strip towards the front of the rig keeps it level along with the square of 1/8" hardboard which rests on the subwoofer grill (2015 and up JK's with the Alpine Speaker option). the double strips near the back of the Jeep are just to fill a hole visually.
to prevent any bass rattles i'm re-using the little neoprene matt i incorporated previously on top of the subwoofer grill.
i went a little shorter this time on the whole base. at 32" deep i am able to use the rear seat mounting bolts that stick up through the floor as locators. this platform presses right up against the back edge of the bolt in each corner.
this puts the rear edge where i can still remove the factory plastic cover that hides the jack.
i went with 39" wide again, which meant i still needed to shave off a little material from the bottom in one spot on each side.
that little cutout allows it to sit flat where the factory side plastic sticks out most.
i again mounted the base to the 4 factory tie-down holes plus the same 2 extra spots where i had inserted U-nuts before. this time i used a flat wood bit to make recess in the plywood and will use pan-head screws along with washers for extra strength.
for the top of the drawer's case, i followed the factory plastic/carpet curves. not so much for visual reasons, but since i'm sleeping on it, i didn't want a hole between the edge and side of the Jeep to let the mattress squish down into.
i bought a contour gauge to help get this part done, and first made a template out of some 1/8" hardboard.
here's the whole structure assembled with just a few screws for a test fit.
i also cut the pieces for the new folding sleep platform that will attach and sit level with the drawer case.
i learned some new stuff already. be sure to see my other post on how to make stronger corners easily with pocket holes. and my tip about buying plywood!
i got over my issues using a router and found a way i could remember which way to feed it. i used to get confused over clockwise/counter-clockwise depending on whether you're routing inside or outside of a shape... but i found this easier to remember: just always PUSH the router AWAY from you and keep it to the RIGHT side of the wood that's being cut.
and so i was able to use a 1/8" round-over bit to ease the edges on everything i made so far.
currently waiting on some locking drawers slides and piano hinges that i ordered before i can go any further, but i'm very happy with the progress so far.