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theksmith

JK Unlimited Rear Storage Solution

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Here's the link to my basket thread

 

https://offroadpassport.com/forum/showthread.php?t=4395

 

I used the angle iron that I had on hand. I'd like to redo it with something lighter and maybe raise the basket I bit higher at the same time.

No current pics as I removed it a couple weeks ago and reinstalled the rear seat. We have friends coming to visit this weekend and I've promised Jeep rides to the kids.

 

I'll take a new pic next time I have the fridge installed with the basket. You've really got me thinking about a slide now, thanks a bunch. Lol! The slide would allow me to move the basket back to nearer the original location which was closer to the gate.

 

ah, i thought you were talking about this thing: http://www.harborfreight.com/500-lb-capacity-aluminum-cargo-carrier-60771.html

 

...and was picturing it maybe fitting like this Teraflex basket:

 

238986.jpg?itok=qgNtabYo

 

FYI, if you do make some sort of slide - someone on expo portal shared this site with me, they seem to have some of the best prices on heavy duty slides (both regular and lock-in/out): http://truck-hardware.orrorr.com/category/drawer-slides

 

and yes, i do like the King plastic products - though if you have time/money to line-x or raptor-line wood, it's just as nice looking and waterproof. note that for this false floor i used StarLite, but for the tailgate table i used StarBoard. StarLite has air bubbles in the core making it lighter but giving it a rough edge that is hard to clean. i didn't think it mattered for a black floor with only one edge showing though.

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check out these floor and side panel modules for JK's: https://www.goose-gear.com/products/jeep-jku-floor-plate-for-2007-2010-4-door-jeeps

 

30.jpg?v=1474257044

 

i can appreciate the effort that went into designing and manufacturing something like this. unfortunately it's probably being sold at such a low volume that even with the seemingly high prices, i doubt there's much profit in it for them currently.

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new stuff...

 

my fridge slide doesn't let the fridge come out far enough to open the door a full 90* where it will stay up on its own. a small gas spring strut was used to fix that issue. now i can use both hands to root around the contents. any strut around 7" to 9" long with ~30N to 50N of force should work.

 

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a CESS 40" foldable stainless shovel was mounted using Mini Quick Fists. i'm used to having a full-size shovel, so the shorty feels a little wierd. however, it seems large enough and plenty sturdy for real trail use (the folding mechanism is uncommonly beefy).

 

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i wanted a dedicated place to stash a few commonly used items without having to remove a bungee or tie down and open a bag all the time. i found what i was looking for at The Container Store - one of their Elfa series medium mesh drawers.

 

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the track is just some aluminum edge molding that i got from Home Depot in the tile and wood flooring area.

 

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my hanging drawer starting squeaking at every bump in the road. i guess once the paint wore off the basket, the metal-on-metal (slides) was bound to be bad!

 

i really liked having it back there for often needed things like the air hose/gauge, bug spray, baby wipes, gloves, etc. - so i was determined to keep the idea.

 

 

i tried a plastic version of the same Elfa product line next (i had to put in a thicker track for it)...

 

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that came out janky. it was difficult to slide when it was cold, yet on really warm days it got so flimsy that it would nearly fall out of the track.

 

 

so i stopped messing around with cheap solutions and bought an aluminum 2U server rack drawer from Penn-Elcom.

 

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i just needed to drill 4 holes so i could screw it to the bottom of the shelf, and i took a jig-saw to the mounting tabs on each side. oh, i did add a couple rubber bump-stops to the back side of the drawer face too. it's sturdy, opens/closes/latches smoothly - and no rattles, squeaks, etc.!

 

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at $100 with shipping, i guess it might seem expensive for just a drawer. however - considering the cost of a nice latch, some slides, and an aluminum box (and being able to just-stop-effing-with-it), it seemed an OK value to me. the steel version is only $50, but twice the weight.

 

several companies make multiple height versions of these, and there are even extra short and extra long ones in the steel edition from Penn-Elcom. sometimes you can find them on eBay with dents/dings for cheaper. i also considered using a cash register drawer, but those were expensive even used, and heavy.

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made a couple revisions...

 

 

new track

 

with the Starlite floor being fairly flexible it would bow up a lot when trying to cinch down a ratchet strap to the short sections of tie-down track. i replaced all the mini tracks with continuous pieces which distribute the load better (and this track is a little thicker too).

 

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the new track was purchased as a single 100" piece that i cut into the necessary lengths: http://amzn.to/2jRarnV

 

 

new slide latch setup

 

i also needed to move the fridge slide latching mechanism a little closer to the fridge to free up some space for the sleeping platform that i'm working on. i went with a slightly smaller spring indexing pin that i already had while i was at it.

 

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i made the mount for the spring-pin and both striker areas bolt-on instead of welding everything this time. previously i didn't have any adjustability to account for wear (other than moving the spring-pin up and down). each individual element of the latch can now be tweaked a bit to dial everything in.

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bed platform / cargo space divider

 

the JKU makes a decent place to sleep, the rear seats fold down nearly flat and there's just enough room for my six-foot-plus-ness to fit with a front seat pushed all the way forward.

 

you do need to fill up a couple major spaces with some extra pillows or whatnot in order to use the full length though...

 

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a removable platform

 

i made a removable extension to my rear "false floor" to take care of those spaces and give a nice stable sleep platform. it's made of that same durable Starlite material and has 3 hinged sections so as to fold up when not in use.

 

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keyhole type picture frame hangers were used horizontally along with 3 screws for a simple but sturdy way to "lock in" to the rear floor.

 

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the sections are then unfolded to create the "head" area over top of the rear seat headrest.

 

lUTNFhxjofTZguZRQrcD7z6vdPU5pt6dQuuF387LiGLGqINOXKZ6IyvcHp0JUmMG9vRNTOAvqGrgwpnijgtjdQmgdd0Q4c0OkpBaQvVsRJcc8a-Fov-WJzePCmsD4ueLvqiwe_G07xglSJE7QKtI3Ri3RH1EtEed9mL1Y7I39PnD-v417Sm5ApfaQAOqbhVSFNCHpD2sFos0BMp2u2acArjGQreQzq7G33WTanlgr32DZKokdrQmbmo773ahJvHvzQuODID0OhVrMP9kSd66RhrmKsZrCDtbOHvPH6niBSVkYFx4Vjm2uYaWMp1NGo1aCb6rPGFAbNBBKvsvZ98XCJ0mJxXwm3cAZcnRggHJwywVbead9GJ914MVXHDkb47RviEsWXy-wfGKjhq09dggQwIrbmI_CJWYTaWIS5LcUBJdP37EjdlKM88MpTx1Hpsk4AzdNIdjszIzU5xwWl1sBmLXWFSf-l_rR1DEWXzH7i0CAZuPnHQVLt7-vgBXu1WuF5TWNdBpIstDr08GGsQSF9LGnrRW7B8GUjuzk3E6FDDWeh2VFnwp5nqInJE8GfXLx407HQDrhTL9CVBddu60wI42KcJRv8J3YD-w50ERMYgkaYoSMSvXAd7LclRf2Cd9z0e_XOePuoud1qhk-_lqyfCscrAslf7DR2pBESBg0w=s800

 

the smallest section acts as a support for this end of the platform. notches were cut to line up with the front seat track so things don't slide around as you get in and out. the large holes were drilled simply to reduce weight.

 

5H5pU0-cABUs0XOF_KfDkIxkvknF4V6F48a1zbrofzC0f6wOMdUDyHet4433ecfuAlHerEK5QTllcySSmZtcnWelRySZTQWUM43EzHf-PTteEm3DQLVO4qa5UUOfybc-spIPafA0Avn4G3cEGQ-cXTzJ_GD05StCnw-1O7O7Fh9G39vOmdmu8XD7wq2EgOxZW-d_P3BLeAEHDMz3mh6Rhr9jqRMYni2O7TTVopvzDsxYFof5WgJV_XpzEaaWewpOi8hm_sAalb1hOB_c1PEdkG3nBfPdFukP7_mJfvy29PzoxbPB6bePy7tXxAunwI15RmAzVLhvDpD6rqjMNEsDHBsaCaGL9SZBya4qjNsDi0dqYyorwBd-XfGHfFe7Yl_jkW06y6eDnOBG7oLPqvYzghuA-AJoIbJnjo-fPUg7csVtBmKwcaY5Fg4a20WLshFgukGPwkfk-_2-5cyJqROsy3slzSjsZQM8_5uqjEZxKH6z3_h-lOHcMcJeYzL536B2dzH30zifnCLT9SwQjvb69qxRTwRzbvAAwkCsz5nZwYP_kwapQXEIS8fSSaZEpmd8Z-gRqdunFHtszgl53qQKJU-k_b-66HiwKffyonT-X50zP_H8t31CG4EpXhzqqAnr7-Jgh28zJkHADImI7H4ZH6oggssjtas88E1JXqGIEw=s800

 

so here you have the basic sleep platform, and yes there's a reason why it's not wider (keep reading!).

 

_0O8rv9ibU-82Qun0pLsCX9n0xXIwGm03e4tvjvPZIvo4lvb09d4YjcWTZzJW6IpmNJsEY9grZw9XDZwZycFWMH1Bl0mIfhwOflTdyS9cyuTq1RxraJAqMyFInP8hpqQRrlSDRWxogLxv2EMenlNjthVYgBEtiLj3bfUrkms4uNoyweFjH2TlY95XZnONrgVaVhDtEEdu0x00pnJ77tFyAoDOsKXP38-uOUv2xDu3_1MRHbs7Z3q7jZ_7oJNSjKN58sc-qN96io4k1KNej2UZZssLe2o1IqSnjHn-40w1NvSApqypq4VmBE90I5m2MIJyObpFHKkcIskhMKzZ7xL4TS5laAYjmCOLdXxQ0g29MOFhpmOs3jnG6JdfRidI33iC3Dp9Hpg_UeCXWjRKqXO7dZWhQBtlEgiuf8hbWSf6YFvoAw5NDCglUPEE-NpPgIi0abkkoPxpOfgTl9R1DkaBmvMg4FG3pWMWlStEpAN8GAeILpSQlTXs-YViMOSjoXotcQz8HgZjuY8Wuw4b7s7I80pfr9T1wSX4rShAvs22VmicayjyvXz4bBuUdKJyDD4on4G74-QKdwzikyQkY8hvt9KM5a3IJJhrbkjW_UTYn5kB1JjU0gkTDIzI_xCe6ljHam2ygDoDQUzn7KSK2PDJ_IYNzHlzBAXmbtBdDDbXQ=s800

 

 

the result

 

it creates sort of a diagonal sleeping area because the area behind the front seat isn't quite inline with the rear cargo foot area (due to the Jeep's center console).

 

vrkYAJ3JsjUHlp8hVclhj0f_2HIu6iu2sfnsgeyCnTEQw6jKQMSIUIk8qfSSrRO6LNAG5_E7fuPNc8WFU5mFF9rYiaV7U9cSFeRpSUZxxVlsrz5MkQresKjHu2e1JSeCb_XkYEo0FhlvUHCyCq94nGNOCKYkBAaIOfl2jZZFOL5SgSPavF7KSiLTl2Q8iO03ZF96drC_R6Usgtz37CFMSDUlo4k4eB3-sTUGRfsi_2Sl6_hhFpo7IgJwSm66IlwddHPd4PY-iyF4Fo0FQlRCbugr6JU-92owagqPVzZ6ufLpQo8rSP7oU88hK6JPwxjSiCgekOLJZHXmo0K-xXk4rLGh4PYk7GCAYqrgaXw-kxUuq_iUkKJpYNWQ9sQO49qodRYfv6W_9ta21eTsMu-U5z_qDjpUnrUSb5ypH_L_VeH4WKV52nvQ46_9_cBX5iQ9y2ZUqiy_cTVrfWM2GuSg_JIAuMJ9VhA9PXU8vV26zX0HqGmYekmSFM1CmQhJrKKlFmRbqZxQ0WzMUqycEoHxX5nlTLvCp-4hcupyqTvjUQHDyFlp0H3-UyDgZI-zjS_GBr2SZ-nTpuBJuZeLyMArXclU5UAzs0jV7N48sE7kvX-VbljCWc90vQOCs2u0rsbY34qtB4MSfboCPPapmS6pmSvt6Us5sMw2cin8ZKtbhQ=s800

 

you can also see that the front of the jeep pretty much has to be the head end because it sits around 3 inches higher than the rear. there's no way to make the entire platform level without raising the rear floor. i have seen some people build short drawers below their rear false-floor in order to level everything out. i actually prefer to sleep with my torso slightly elevated anyway, and the 3" of rise is barely noticeable.

 

i purchased some foam instead of having to deal with an air mattress, but my first order was way to hard (and i like a really firm bed). this was 4" x 24" x 74" and had a firmness rating of 50 ILD.

 

i've since ordered a new piece rated at 36 ILD and went down to 3" thick. the 4" was pretty bulky and didn't seem necessary even to cover up bumps from the tie-down track, hinges, etc.

 

lB5JS7K1x32hmXY5jqXkbj0o8Qak_Kcn0pyvFXMP_o3vhppn-mb0G7QXq5Ruhudkb70SPXVj9rLZMhitwDeozljVBdI-tZRyfsObTt4IE2dMsn6nEINg8T61iHE9MZD0ytOVQzmf4ZQfQmuApnO0GXhbN4LVz9mL8K6cMsczAXA6CLfWcYdNoCtZLgL9_BieysWt7_sVw1DqNNg-GFQKm_k_To-U8h4c9GkToQEUmpPdsDZvtjCVIRdidhCg_DAJ2MxNmeJeW0PO2xSD2sANLwZ33I4WTXXzExV7JnXcH9jITdAV-_yIpRDdieGEVntcefkGqKp-ehkp3zf-pyJMYX9fEU1Rt6KctPMpakxiHbGE362RfUy7-5bMIw9CSVj2PdjQh0b2PNZ1BhaiginWzNbarD5nMMh6CfM2NokH7W3mX_5FB1Qb5451BZ-s_f19Gz6VhhkYs15JMILfjPW1lTV8LoyAiMqJz_x569xmEzco4QVBfgFbKUEDjx2wtyMeWmEMX8B-fg2OdGXBDrK98Lh3nrRuRT-eoIQ5u1RUEWXX_F72RfAMGc4DpUMOeH3JeMtWYZF5di71ffgnz07zdEiOxNdsXRBPsUAoNWRvxEn-N65B61fdeluj0UBLTXNZ2McmLO8WFwgWGJwhgxo15bP0i2r8pWxhvQnfnFQV9w=s800

 

the passenger seat has to be all the way forward for everything to be deployed...

 

jn4QfUDRRp_9YNLVRk8xKAd_wWLOWuldsNxO2Qp3Ck0BLhYzdw4l7nzACUI08-vlfzuEUtfKvKFFI7HqTKGkljbceMHQlWshhCVwSd17FIYSS2BTa2jz_bW2fyAdsKl4b8wixBGyYuYnoLY054qpsJOH84qncqv1Lf-NF_-CbSbaskJ8QRlqg_Z-sZttlgnIeTIVsxIOtSpAnI0DF9te91YokxSEhpeuJGtrYH1CfrvbpV6_uqFgheOisz6Un3aTxiMR3mTTIYwehLSveYlhkigB6T-eQiIAfceGeVYgZaNny2RsPKOoQeBbYho3_5nQDFr87ojlBMtUHcwND_TL2j571PiN9ar4hbVoRRzmVkEko5CIs-nL3_9LcLOh3tIW5nh3NEaf1MwCfjgTHl5Y3QX1ldG6kkfzudS41IbXktGkOyfl-oLa5h0c1oubU0mp9xpFYhsmOC8lHdX3HM0zKgfTqmBzx2lZXiQ8KhPSsEUpwqL9SVgEfvSH4hx1t2le6VGuZVSDd3LhRgqf8ciHQPw_OMf1LpLD0qjKEW9x5N3S0A6zC5Dcx-MW3zTCOLc4iv37F1t_LRbQXXhLjOMqA_b9deB5CQKcIBnylbvYdtzgzCH0PEmpVTj1d_YkiKvy-orkVdwDA2xgoDeYvdNaYHj1arebPHYWg0HEoXJXPg=s800

 

however, i can leave the platform attached and fold up just the front flap in order to get the seat back. it would annoy me to no end to have the seat forward for an entire trip (and block my view)!

 

uftxenql3UITIiA3G5eFZCagIzQkAUJCZL2bdhfcj0o5tXPNTnE8tKLd-RLdrzVzLF_Y4wcf4lKR7qqWz-3XnqB5Nd2I4WO82Lq55mPa6bUY4yC0q0TjHpPkKxyAujcy8GtZtflPTqIYBQ0CFAhmqgNe4YK3yIl3YXwsYy7d9Lsa3STWaiNKNraJHaJkR-Y3FVcHJKZxw6c_10InL8TVS7vroOxl0_igccDQhCQzmzbJbnfzb_8lKK9QuIXk9Me5DdGJN_3eyFv7fTt13tFCrM4pTLq_gxMapUwrR1BKs-falPWcgAJsqtKdS3BQWozcIEnOrvFo4WI7Cv_ltO_K1V5ctokqhEXNaQYmR3IGOJ3JxTOM5cOG9SWnXXRL7GCb0jFuR3GqhNjxZDWgEJjvzORHAyIvPbpVP-WyH4uBvek-ZADp6lybrmQJMN7ouZhHW-Nc9lOcmH108eDO9Fgg-BAyLiO4lolFJmUo2Hw2eQXaacFdAaNGqk34kw8eAK9zVsaw-LBNKt-m7Uxvodm2_zM9HL1cpBDcxVSZL1XHCjYr6EmwPcGdB1uEPRK1WIp9WNb6BFkOL2RoGgWO11rzwFse-aVTiLjvd_yr5DKX-zoCsuCCl9alHero02QuWcYvI2eM2D2BlBklHMDc8xthS1zXotqfX8a7O8GdIz-qcQ=s800

 

 

dual purpose

 

my initial plan was to make the platform be the entire width of the large side of the rear seat and have it permanently hinged to the false floor in the back...

 

however, i also intended to put up some sort of divider between the fridge and the cargo area so that i could shove a bunch of random stuff in there and not have it fall into the slide area when the fridge was accessed. it dawned on me the bed platform could serve that purpose as well since i would never need both at the same time (if the back is full of stuff i can't sleep in it too).

 

so here's the platform acting as the cargo divider:

 

283dYVvvdXywhryNEMGytFGx7Kye1Co16JmmjSVIdvcRP0gwddR82igvDx9qk3PYrUSVGMAy78dLRzGdqhEKpuEe2o03bGwmExqbuq9SUSJwgQtsfnF6h8HcNRyABncy77dvo9Ub7qx0dAgnEbGNb2UeTr4umEetoCEQJnt0U8JSPAIjGhNdXh7jinRDLl4TmfsOCBvVgpYWQcb0kAZ24CZN7-UfdARodp2_wm-_7RcOq7e3rQk3ZSrpxTKFJthBqKWX2BoBDIsQvRsQ971HAbmGFwZ5GnN2-MMR1qe7CTEId9qHp18uNOhpXheZJz3_Q2rmfDmuqvfONOMrt9GZygxu88INcYg-tIDQ4et-0qyTsTAeAsPAOWL-rdrlCRaVc3Hqke4B2tIH3qUsty0o6OdKkEz93VJQdzhPsc9T2F6-WwOp1bGCqHpG8IN64C5lDswDaGSZBHOqLXH99PnL5EY_qc9o-U_r7vzoqbqZ6rJI4U8vzynw7wTQ6FhlWFzwwU9Lh7u3jP9ndxbayEXA0acJ6WIOvvdgYvoknozvBuO_A2stfDs_B-0BbCaXjfHSiu0r2eLsfZ52mlmt33SCYzXrfk2AcJTRb__nCUpV4Suo8ndqkddIieFi9xyAfD36O9Cnk06xxxWdMU7n-mAg0dsHZbP_dp2Sj9EAXxSkaQ=s800

 

beyond keeping junk from falling onto the fridge slide, it also keeps that junk from sitting right against the fridge's vent and blocking air flow.

 

to stow the platform as the divider, it simply slides into tracks i made from aluminum channel:

 

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it's currently just held in place with a tight friction fit, but i may need to add some sort of stops later as things wear.

 

thin magnetic catches hold the hinged sections closed so nothing rattles (though i've only tested on a short gravel road so far).

 

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items used in this project:

 

- piano hinges: http://amzn.to/2jouA5W

- stainless screws: http://amzn.to/2iK1ifU

- t-nuts (stainless was too expensive): http://amzn.to/2iK8d8J

- magnetic catches: http://amzn.to/2iK7RPL

- original foam (seen above): http://www.foambymail.com/conventional-seats-and-cushions.html

- new foam ordered: http://amzn.to/2iJWAPt - UPDATE: do NOT buy this one - it gave off noxious fumes even after a week!

- cut to order Starlite material: http://www.boatoutfitters.com/Raw-Material/King-Plastic-Black-King-Starlite-Plastic-Sheet-13770-42204-346.html

- keyhole hangers, 1/2" opening aluminum channel, 1/8" x 1" aluminum bars for spacers, misc screws: the local Ace Hardware

 

 

once i get the new foam, i'll have to get Aimee to take a pic of me in there so you can see how the space actually works out with a person.

 

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Great design, and as always, very well executed!

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thanks Jim!

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BTW: after you gave me the sample of Starlite material and shared your concerns about stiffness I did some digging of my own.

 

I was looking at getting 1" Starboard, 2 pieces, cut to size, from Boat Outfitters. The total for my project, including shipping was $108.

 

I found this on EBay:

http://www.ebay.com/itm/1-WHITE-BLACK-KING-STARBOARD-CUT-YOUR-SIZE-/300756576561?hash=item46067d2931

 

I bought slightly more material to meet his 3 sq ft minimum and qualified for free shipping. Total price, shipped, $74 I just need to make one rip cut and one cross cut.

 

I called the shop to clarify something, good guy to deal with.

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BTW: after you gave me the sample of Starlite material and shared your concerns about stiffness I did some digging of my own.

 

I was looking at getting 1" Starboard, 2 pieces, cut to size, from Boat Outfitters. The total for my project, including shipping was $108.

 

I found this on EBay:

http://www.ebay.com/itm/1-WHITE-BLACK-KING-STARBOARD-CUT-YOUR-SIZE-/300756576561?hash=item46067d2931

 

I bought slightly more material to meet his 3 sq ft minimum and qualified for free shipping. Total price, shipped, $74 I just need to make one rip cut and one cross cut.

 

I called the shop to clarify something, good guy to deal with.

 

 

nice find! you can also buy "Seaboard" on Amazon by the full sheet and it is a little bit cheaper than actual King Starboard. - they don't appear to sell Starlite though (which is the lighter material i used for all this floor/platform stuff).

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