Custom boxes on top of wheel arch

[ProjectDirector]

My best man is a cabinet maker and wants to make me a couple boxes after Easter.
They will go on top of the wheel arches which will have the same width as wheel arch and about 950mm long. I lost some length due to cargo barrier. So am looking for the best way to make this box to maximize internal space. It will have a lid to open up toward the side window.
I will need to bolt it on the side where there two blanks made for 3rd row seats. Not sure though if I need to bolt it on the wheel arch.
Anyone with similar project and their recommendations will be good.

[Drover]

No help with the boxes, but they sound like they would be a terrific pairing with a set "gull-wing" side windows......just say'n !

[Defender08]

In the Puma there are a number of nuts (look like 8 mm thread) welded under the wheel arch. I presume that where 3rd row seats are added, then holes are drilled in the wheel arch to give access to these nuts. They look like very sturdy connection points.

[110 Pete]

Hey Mate,

I have exactly what you have described. Mine are made from ply wood covered in marine carpet. The are just bolted through the wheel arches. I have 2 6x9 Speakers mounted in them and keep recovery gear, Bottle jack, axe, shovel rope and various bits and peices. They are perfect size and dont take up much room at all.

Cheers

Pete

[Xtreme]

Something like this, I guess - only better finished if built by a cabinet maker or covered with marine carpet.
For years I used a couple of milk crates but since replacing them with the box I find it much tidier and it takes up less room. I didn't fit lids as I considered that they would restrict access too much.

https://www.aulro.com/afvb/images/imported/2014/04/780.jpg

The fridge is a semi fixture on the LHS and even though I'm a shortie, I don't find access a problem. I'm not a fan of fridge or drawer slides and feel that they add unnecessary weight and take up extra space.
https://www.aulro.com/afvb/images/imported/2014/04/781.jpg

I like to have access to gear as needed, without needing to unload unwanted items, hence the multiple levels as seen here.
https://www.aulro.com/afvb/images/imported/2014/04/782.jpg

The fridge and Box are attached to a tubular steel framework that I fitted to each side of the rear load space and, as can be seen, the LHS also houses most of my extra electrical gear - utilising the curve in the bodywork and is out of the way.

https://www.aulro.com/afvb/images/imported/2014/04/783.jpg

https://www.aulro.com/afvb/images/imported/2014/04/784.jpg

[ProjectDirector]

Hey Mate,

I have exactly what you have described. Mine are made from ply wood covered in marine carpet. The are just bolted through the wheel arches. I have 2 6x9 Speakers mounted in them and keep recovery gear, Bottle jack, axe, shovel rope and various bits and peices. They are perfect size and dont take up much room at all.

Cheers

Pete
Fantastic, any chance for a couple of photos?
Did you bolt them on the wheel arch?

[ProjectDirector]

Something like this, I guess - only better finished if built by a cabinet maker or covered with marine carpet.
For years I used a couple of milk crates but since replacing them with the box I find it much tidier and it takes up less room. I didn't fit lids as I considered that they would restrict access too much.

https://www.aulro.com/afvb/images/imported/2014/04/780.jpg

The fridge is a semi fixture on the LHS and even though I'm a shortie, I don't find access a problem. I'm not a fan of fridge or drawer slides and feel that they add unnecessary weight and take up extra space.
https://www.aulro.com/afvb/images/imported/2014/04/781.jpg

I like to have access to gear as needed, without needing to unload unwanted items, hence the multiple levels as seen here.
https://www.aulro.com/afvb/images/imported/2014/04/782.jpg

The fridge and Box are attached to a tubular steel framework that I fitted to each side of the rear load space and, as can be seen, the LHS also houses most of my extra electrical gear - utilising the curve in the bodywork and is out of the way.

https://www.aulro.com/afvb/images/imported/2014/04/783.jpg

https://www.aulro.com/afvb/images/imported/2014/04/784.jpg

Super thanks, this is exactly what I want to do with spare battery, I want to install it in one of the boxes on the left side.


I just need to buy the marine carpet and my best man will provide the ply and labour to build, so am getting a good deal here.

[steane]

I'm half way through a similar build but for a hardtop. Two 1300mm long boxes on each wheel arch that sit just below the window line. One houses a 58ltr water tank and pump and the other an aux battery and ctek. Both have separate storage compartments towards the rear so weight is kept closer to centre of vehicle and storage can be accessed easily from the rear.

Lids won't be hinged, they will be a routered fit and have latches at each end set into the top of the lid. I'm not convinced hinge screws into ply will last long on rough roads.

My boxes are larger than the wheelarch tops as they fit snugly against and will be bolted to a 660mm wide x 400mm high (approx) centre drawer box. The gap between the drawer box and the sides of the wheelarch will be where I run power and water to the rear.

I'm using 17mm form ply. Has a black coating on both sides that keeps it all looking neat but is harder to work with as the coating needs to be routered off so glue works. Galv screws and selleys durabond on all joints. Will weight around 120kg including a set of 227kg drawer slides.

Will transform the useable space and mean I dont need to unpack the back to get to things.

[ProjectDirector]

I'm half way through a similar build but for a hardtop. Two 1300mm long boxes on each wheel arch that sit just below the window line. One houses a 58ltr water tank and pump and the other an aux battery and ctek. Both have separate storage compartments towards the rear so weight is kept closer to centre of vehicle and storage can be accessed easily from the rear.



Lids won't be hinged, they will be a routered fit and have latches at each end set into the top of the lid. I'm not convinced hinge screws into ply will last long on rough roads.



My boxes are larger than the wheelarch tops as they fit snugly against and will be bolted to a 660mm wide x 400mm high (approx) centre drawer box. The gap between the drawer box and the sides of the wheelarch will be where I run power and water to the rear.



I'm using 17mm form ply. Has a black coating on both sides that keeps it all looking neat but is harder to work with as the coating needs to be routered off so glue works. Galv screws and selleys durabond on all joints. Will weight around 120kg including a set of 227kg drawer slides.



Will transform the useable space and mean I dont need to unpack the back to get to things.


I won't be using drawer in the middle. I will leave middle as is so I can put the fridge and other things. This is my daily vehicle and need to have free space, load it only when I go on trips.
The whole design will be based on modular type.

[numpty]

I have a similar thing and if I get a chance today I'll take a few pics and post them up.

As suggested, a gullwing window would be a great addition as well.

[ProjectDirector]

I have a similar thing and if I get a chance today I'll take a few pics and post them up.



As suggested, a gullwing window would be a great addition as well.


That will be great, looking forward seeing your photos too.

[uninformed]

I'm half way through a similar build but for a hardtop. Two 1300mm long boxes on each wheel arch that sit just below the window line. One houses a 58ltr water tank and pump and the other an aux battery and ctek. Both have separate storage compartments towards the rear so weight is kept closer to centre of vehicle and storage can be accessed easily from the rear.

Lids won't be hinged, they will be a routered fit and have latches at each end set into the top of the lid. I'm not convinced hinge screws into ply will last long on rough roads.

My boxes are larger than the wheelarch tops as they fit snugly against and will be bolted to a 660mm wide x 400mm high (approx) centre drawer box. The gap between the drawer box and the sides of the wheelarch will be where I run power and water to the rear.

I'm using 17mm form ply. Has a black coating on both sides that keeps it all looking neat but is harder to work with as the coating needs to be routered off so glue works. Galv screws and selleys durabond on all joints. Will weight around 120kg including a set of 227kg drawer slides.

Will transform the useable space and mean I dont need to unpack the back to get to things.

IMO if you were to use piano hinge I think youd be fine screwing into 17mm ply. But I do like your idea of having them drop in, that means the lids can be fully removed out the way, and may provide a dual use?

Sounds like you are using a sort of form ply. If you are worried about vibrations, maybe use a flexable polyurethane adhesive

[steane]

IMO if you were to use piano hinge I think youd be fine screwing into 17mm ply. But I do like your idea of having them drop in, that means the lids can be fully removed out the way, and may provide a dual use?

Sounds like you are using a sort of form ply. If you are worried about vibrations, maybe use a flexable polyurethane adhesive

I think drop in lids will actually be easier and more convenient to use. Like you say it also allows for dual use. Fitting items in that will sit above the lid when needed, without the lid getting in the way or flapping around.

Should be right for vibrations, it's a very strong construction. The drawer and side boxes are also sitting on (and bolted through) 10mm closed cell foam and marine carpet, so that if I remove the drawer and side boxes (it's modular so removes easily) then the tub will still be carpeted. Should help dampen the vibes a little at least.

The Raids will have to do the rest;)

[Bushie]

Pics of mine. One bolt through the wheel arch towards the rear, and another near the front, but can't remember what it secures to without going and having a look :cool:

https://www.aulro.com/afvb/images/imported/2014/04/689.jpg
Watertank behind the box across the load barrier.


Martyn

[KeithMac]

Pics of mine. One bolt through the wheel arch towards the rear, and another near the front, but can't remember what it secures to without going and having a look :cool:

https://www.aulro.com/afvb/images/imported/2014/04/689.jpg
Watertank behind the box across the load barrier.


Martyn

I like your set up Bushie. What do you have underneath the centre? Draws?

[Bushie]

Earlier shot

https://www.aulro.com/afvb/images/imported/2014/04/690.jpg

Obviously the fridge has moved (replaces the single seat in the rear) now we aren't transporting the kids, but the draw is the same. Pretty simple setup.


Martyn

[ProjectDirector]

Pics of mine. One bolt through the wheel arch towards the rear, and another near the front, but can't remember what it secures to without going and having a look :cool:

https://www.aulro.com/afvb/images/imported/2014/04/689.jpg
Watertank behind the box across the load barrier.


Martyn


This is neat am impressed. Is that marine carpet you have?

[Bushie]

Just cheap waterproof carpet from Bunnings.


Martyn

[ProjectDirector]

Just cheap waterproof carpet from Bunnings.


Martyn


Thanks I will keep it in mind

[Leroy_Riding]

the Carpet always seems to make the job look a lot more 'polished'

Ive been using my draw for a few months now as bare ply wood, it makes camping and day to day so much easier, still a little work to do before I can carpet it though.

I two plan to fit 'under window boxes' though have been holding off till I can afford gull wing doors.
what is your plan to access the boxes? are you going for full length boxes or jsut near the factory windows opening?

whatever you make, be sure to post photos for the rest of us :)

Leroy

[ProjectDirector]

I don't plan to change windows. The idea of these boxes is to keep middle section clear for fridge and I will access boxes from inside. I am a minimalist and will only carry what I need. The new roof rack will carry tent, sleeping bags, self inflating mattresses small plastic table and folding chairs from bunnings ie all lightweight.
Planning to do boxes after Easter time permitting.

[isuzutoo-eh]

I have some very expensive tailor made boxes along one wheel arch, some people call them milk crates. The other wheel arch gets the longer stuff-chairs, table, self inflating mattress, sleeping bag etc on it. Food and cooking boxes in the middle, fridge in back seat footwell.

[numpty]

Pics as promised

https://www.aulro.com/afvb/images/imported/2014/04/591.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/008_zps138c0b2a.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/04/592.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/007_zpsb10bf232.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/04/593.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/009_zps39dd495d.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/04/594.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/010_zpsd413a1c1.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/04/595.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/012_zpsa7b1c78f.jpg.html)

https://www.aulro.com/afvb/images/imported/2014/04/596.jpg (http://s1167.photobucket.com/user/Perry1953/media/Defender/013_zps56ebe6e3.jpg.html)

Apart from the drawer front and top, this is all made from 9mm ply and covered in marine carpet. Only existing holes/screw fixings were used and custom brackets made where necessary. In the rear corners you might just see some curved 25 x 3 flat bar, fashioned to hold 2 gas cylinders, which are held in with straps (actually fire helmet chin straps) ;)

The centre 3 boxes can be removed by undoing half a dozen screws.

[ProjectDirector]

Numpty, looks like you have done a great job and many thanks for the pics. Gives me some ideas now and hopefully after eAster I will visit my best man and start process only for side boxes. Have a safe Easter.