DIY Rear door shelf for a Puma

[The Cone of Silence]

Finished the folding rear door shelf today.

Due to the size restriction as a result of the bulge in the door panel thanks to the puma windscreen wiper mechanism, the shelf needed to be foldable into two halves.

11mm ply, topped with marine carpet and edged with some L-section from good old Bunnings. 2 continuous hinges for the folds and a couple of pad eyes with some swaged 2mm cable for the support.

Fitted it to a piece of chequerplate using pop rivets and then fitted the chequerplate through the panel to the door with 3 rivnuts at the top and 4 nuts and bolts at the bottom which just secure the chequerplate to the door lining with some nice big washers.

Can't wait to make my first cup of tea using the new dual fuel too, for which the shelf was made. This was a really enjoyable little project after the more sizeable drawer and "long stuff" channel. Easy for anyone to do.

If anyone's interested in doing this PM me and I'll send through info on basic dimensions, materials and tools used.

Bobby

p.s. Mulgo gas strut fitted too - the slope toward the kerb is greater than the pictures suggest and the strut still holds the door at almost 90 degrees. Nice piece of kit - thank you Daniel.

http://www.aulro.com/afvb/attachment.php?attachmentid=49036&stc=1&d=1342249777

http://www.aulro.com/afvb/attachment.php?attachmentid=49037&stc=1&d=1342249777

http://www.aulro.com/afvb/attachment.php?attachmentid=49038&stc=1&d=1342249777

http://www.aulro.com/afvb/attachment.php?attachmentid=49039&stc=1&d=1342249777

Taking over the street. I really need a garage/ workshop!
http://www.aulro.com/afvb/attachment.php?attachmentid=49040&stc=1&d=1342249777

[Didge]

excellent job, I like the bifold concept :)

[Drover]

Nice work Bobby, clever idea with the fold...

Cheers

[Nera Donna]

Very clever. Well done[thumbsupbig]

[The Cone of Silence]

Thanks guys. I'd love to take credit for the idea but the inspiration came from a Qantas exit row armrest tray table, which I've only sat in once or twice* but was suitably impressed with.



*because like most Land Rover Defender drivers, I suspect, I only have little legs!

[MacMan]

Clever design, although I would have done the "top" section with rubber or something easier to clean than marine carpet since it's a cooking area. Otherwise full marks! :D

[The Cone of Silence]

Good thinking MacMan.

As long as I'm using the dual fuel, the carpet should stay clean but I'm pretty sure I'll also use the shelf for puting and spilling cups of tea on and preparing food....maybe I should cut a piece of ply to fit to act as a chopping board. Could live in the drawer I suppose.

Will give it some thought!

[MacMan]

Also nothing stopping you just having a rubber protective mat that rolls up on top. Chopping board idea is a good one.

[dmdigital]

Well thought out :)

Making it out of the chopping board plastic would be another option.

[chook73]

Looks great well done, its one thing that bugs me when traveling with 80 series and hilux people is the fact that they have an instant table when pulling up for lunch or short breaks.

Might put this on the to do list..........

[The Cone of Silence]

Christened it on Saturday up in the Watagans.

The lads made ham, cheese and pickle rolls on the Hi-Lux shelf while I made tea on the Defender one.

Very happy with the Coleman dual fuel too - no chance of any heat getting to the door or the carpet and it cools down really quickly after use too. A big but excellent unit.

http://www.aulro.com/afvb/attachment.php?attachmentid=49287&d=1343011227

[ad91on]

I made tea on the Defender one.



TYPICAL defender owner :P

awesome little shelf! How much did it cost to build approx?

[The Cone of Silence]

I think about $200 or so as I needed the odd tool too. I can't remember - my vision and memory get terribly clouded in Bunnings. Must be something in the sausages.

Ingredients:
1 sheet of alu chequerplate
1 small sheet of 11mm Ply
2 x continuous hinges
4 x 1m lengths of Alu L-section
Marine carpet
6 x pad eyes
2mm cable
4x Swages and 4x thimbles
Screws, Rivets, Rivnuts and bolts
Tea
Band aids
Tolerant and/ or partially deaf neighbours

Tools:
Drill
Countersink
Jigsaw
Circular saw
Stanley knife
Rivet gun
Swaging tool
Spanners
Screwdriver
Kettle

I'll let you work the recipe out yourself, but drop me a PM if you want me to run through the steps and tips I learned along the way. ;)