110 Rear Shelf Design

[DamosDefender]

Afternoon Guys and Gals

i thought as i am trying to hide from the sun today i would design a rear shelf for the back of the PUMA.

I had two options in mind, one: use only wood or two: use ally square tubing and wood (PLY). i was towards the ally tubing and wood for weight and easy to construct. I'm wanting to use the system they have at Bunnings with the pre formed corner join for the square tube.

in order to strength and be more permanent i was thinking of Riveting the corner joining pieces and the tube together.

Ally tube
Connect-it 25.4 x 25.4 x 1.2mm 1.8m Anodised Aluminium Square Tube (http://www.bunnings.com.au/connect-it-25-4-x-25-4-x-1-2mm-1-8m-anodised-aluminium-square-tube_p1138301)

Plastic Joinery
Connect-it 2 Way Corner Joiner | Bunnings Warehouse (http://www.bunnings.com.au/connect-it-2-way-corner-joiner_p1138466)

i have attached a design i made up in Sketchup to get a rough idea of what I'm trying to achieve.

i would appreciate if you all can critique and give your opinions towards how the layout should be and best materials to use (i.e. marine ply , marine carpet, spacing of ally support....) o and any photos of you guys set up.

Cheers

Damo

[manofaus]

If it was me i would look at just one material. You can easily make something strong with just timber and it is easier to shape. Go for marine ply and get into the practice of good glue and prep. Drifta make complete camping kitchens outta the stuff and you will find it hard to hear of anyone knocking their stuff about failure.

[defender_i_hardly_know_er]

I built mine for my D90 out of the same stuff. With more or less the same design but with a 900mm long drawer.

I'm going to rip mine out next year and build the shelf higher, to fit my fridge in below. At the moment it sits on top of the shelf and the feng shui is all wrong.

The ally/connect-its stuff is pretty good and goes together really quick.

[DamosDefender]

If it was me i would look at just one material. You can easily make something strong with just timber and it is easier to shape. Go for marine ply and get into the practice of good glue and prep. Drifta make complete camping kitchens outta the stuff and you will find it hard to hear of anyone knocking their stuff about failure.

you have a very good point i have looked at there products and they look the part and have only heard good stuff about it, so its the the little bit of weight worth the strengths and end result?

cheers

[DamosDefender]

I built mine for my D90 out of the same stuff. With more or less the same design but with a 900mm long drawer.

I'm going to rip mine out next year and build the shelf higher, to fit my fridge in below. At the moment it sits on top of the shelf and the feng shui is all wrong.

The ally/connect-its stuff is pretty good and goes together really quick.

thats what i like the ease of constructing it can i be a pain and ask for a photo just to see how it sits??

cheers

[Witchdoctor]

Sorry for what may seem a negative word
Wood may be easy for the average Jo to work with but it is bulky & heavy!


Cheers

[karlz]

Must of been thinking the same thing today.

Been thinking of shelving system for the 110 for months.
Cant justify over $1200 for a single drawer that looks nice.
Yeah I would like one, but the money saved could be best spent somewhere else.

So Ive been looking at building a system.
My last vehicle (P38) I built a box, but the defender is more simple.
The defender already has supports (alu wheel arches) inbuilt into the interior!

I reckon I'll just buy some plywood, a flat sheet, cut it to size, carpet it and mount it across the rear.

So I went to Bunnings (masters wont cut plywood), bought a sheet of 15mm CD ply and had it cut 1610 x 980. $60
GUess what? You cant get it in the car and fit flat across the interior wheel arches!
So, I will need to make that single piece 2 pieces tomorrow.

ps. rethinking the 15mm option. Reckon I need 19mm

I may even post a few pics!

btw, I dont want a drawer system, but I will continue to use those plastic under bed boxes you can get from bunnings as well. Just as good I reckon.

[digger]

I have no photos of the one I built for my previous defender.

But, it was marine ply,
what I wanted though was the option to remove it without problems.
so I measured the distace diagonally between the top and bottom of the door and made it about an inch shorter than that. I put one central solitary leg (running the length of the board front to back.) This means that the leg doesnt get in the way when fitting or removing.

I had a cargo barrier fitted and when I did thet I fitted a child seat hook on the floor at the foot of the barrier on the cargo side (there was a hole in the barrier for the seatbelt to pass through) Above this i cut a square out that way easy enough to put my hand through, I fitted a piano hinge and cut a hole big enough to lift it open with my finger - small piece wood across top to add as a lip for the door to sit on.

I then cut grey/black marine carpet to the size of the back of the defender, (so about 1-2" wider than the wood) glued on top of wood and cut the little door shape out so it would open!!

On both sides at the back I fitted eyelets hanging down just inside (about 2" in from the edge) and fitted adjustable turnbuckles between the eyelets and the tie down points, this secured it nicely.

I fitted 1 x chicken crate and one banana box in either side, thats a lot of storage.. Best of all it could come out or go in quickly and without fuss, and carried a very heavy load unfussed!

I fitted a "defender" badge (from a kero fridge) on the middle leg if anyone finds it.... I loved that car...

Hope that makes sense

[rar110]

I made a high shelf in the cargo area by bolting two pieces of steel angle (12mm angle with 6 mm bolts I think) to the inside roof sill which spanned the width of the inside. The angle supports a 9mm piece of marine ply screwed to angle and covered in carpet. It's very high but holds stuff like chairs and plastic boxes of cooking stuff. Very handy.

[rar110]

Here's a pic to explain better. The roof lining is down atm as I'm doing some work on the 110, in case that causes some confusion.



102188

[DamosDefender]

Must of been thinking the same thing today.

Been thinking of shelving system for the 110 for months.
Cant justify over $1200 for a single drawer that looks nice.
Yeah I would like one, but the money saved could be best spent somewhere else.

So Ive been looking at building a system.
My last vehicle (P38) I built a box, but the defender is more simple.
The defender already has supports (alu wheel arches) inbuilt into the interior!

I reckon I'll just buy some plywood, a flat sheet, cut it to size, carpet it and mount it across the rear.

So I went to Bunnings (masters wont cut plywood), bought a sheet of 15mm CD ply and had it cut 1610 x 980. $60
GUess what? You cant get it in the car and fit flat across the interior wheel arches!
So, I will need to make that single piece 2 pieces tomorrow.

ps. rethinking the 15mm option. Reckon I need 19mm

I may even post a few pics!

btw, I dont want a drawer system, but I will continue to use those plastic under bed boxes you can get from bunnings as well. Just as good I reckon.

thanks for the heads up on needing it in 2 sections that could been a heart ache, I'm wanting to do it in two stages so i can build a draw in it later but my just stick with some plastic boxes to see what will work best and what exactly i will be holding in it.

cheers

[DamosDefender]

I made a high shelf in the cargo area by bolting two pieces of steel angle (12mm angle with 6 mm bolts I think) to the inside roof sill which spanned the width of the inside. The angle supports a 9mm piece of marine ply screwed to angle and covered in carpet. It's very high but holds stuff like chairs and plastic boxes of cooking stuff. Very handy.

thats a nice set up and a good idea thats one for the ideas list

[defender_i_hardly_know_er]

thats what i like the ease of constructing it can i be a pain and ask for a photo just to see how it sits??

cheers

Here you go.

[JLo]

Afternoon Guys and Gals

i thought as i am trying to hide from the sun today i would design a rear shelf for the back of the PUMA.

I had two options in mind, one: use only wood or two: use ally square tubing and wood (PLY). i was towards the ally tubing and wood for weight and easy to construct. I'm wanting to use the system they have at Bunnings with the pre formed corner join for the square tube.

in order to strength and be more permanent i was thinking of Riveting the corner joining pieces and the tube together.

Ally tube
Connect-it 25.4 x 25.4 x 1.2mm 1.8m Anodised Aluminium Square Tube (http://www.bunnings.com.au/connect-it-25-4-x-25-4-x-1-2mm-1-8m-anodised-aluminium-square-tube_p1138301)

Plastic Joinery
Connect-it 2 Way Corner Joiner | Bunnings Warehouse (http://www.bunnings.com.au/connect-it-2-way-corner-joiner_p1138466)

i have attached a design i made up in Sketchup to get a rough idea of what I'm trying to achieve.

i would appreciate if you all can critique and give your opinions towards how the layout should be and best materials to use (i.e. marine ply , marine carpet, spacing of ally support....) o and any photos of you guys set up.

Cheers

Damo


Damo
I built mine very similar to your sketchup design using the plastic corner joins. I centred the middle support though as I have a 60 litre fridge. I used 8mm ply as the top board, covered in marine carpet. The whole thing is held down by 2 small angle brackets through the arches. I haven't had any issues with sagging or breaking of the plastic corners in 13 years of hard use. I would build the same again. Double check the squareness of the load area before you cut the tubing. Cheers JLo

[Didge]

For those of you using sketchup, do you know how to:
create a component or group and then multiply it numerous times? or conversely, divide it into a given length? If not, I'll answer it for you :)

[Marty90]

Here's a pic to explain better. The roof lining is down atm as I'm doing some work on the 110, in case that causes some confusion.



102188

This is a top idea.I was thinking of hooking a "mesh" from the roof somehow,but this looks much neater. Just one question though.What supports the middle?

[karlz]

Here you go.

Brilliant. Exactly what I was after. Thanks

[rar110]

This is a top idea.I was thinking of hooking a "mesh" from the roof somehow,but this looks much neater. Just one question though.What supports the middle?

Thanks, nothing supports the ply other than the front and rear section of angle, which is held in place by 4 bolts. It's only 600mm deep from memory. I was going to support the front on the cargo barrier. But not needed. As I said I only use it for 4 x camp chairs and short kitchen boxes. It works really well as you don't have to unload stuff to get to the chairs.

[digger]

Instead of getting 2 pieces and having to sort out where the join goes and how
To support it, at least consider the way I did it. Measure diagonally top to bottom of your door go just under this and that will leave about 1 or 2 inches either side the wood doesn't move because of the
Turnbuckles and the central leg means it will support just about anything... Just trying to "uncomplicate " things!!

The black or green veggie or chook crates fit well, I had Bilo bannana boxes with lids in front of the crates with ropes and hoses etc.. Now it'd e tools as the tool box is full of wires/relays and fuses!

[Onetenland]

Hi Damo
I just finished building your exact same design three weeks ago.
However I just used ply for the whole thing. 19mm ply, dark grey marine carpet.
Just watch out ,the largest piece of ply you will be able to fit in the back is approx 1510 x 600. I did the top in two pieces and fitted two vertical rails under + the carpet in one piece.
Instead of glueing the carpet down I cut it 6 inches bigger all round and tucked it under.
It was a bit of mucking about but it came up nice. Plus with the 19mm you can screw down some locking track pieces to secure your load. Installed it sits about 220mm high leaving a large area underneath to fit a couple of black tubs from Bunnings for another $20 each. Far better and cheaper than a $1000 drawer setup.
The whole thing cost about $200 including tubs and weights less than 15kgs
Cheers

[pommy]

Can you post some photos 110land sounds just what I want to do thanks

[karlz]

Hi Damo
Just watch out ,the largest piece of ply you will be able to fit in the back is approx 1510 x 600. s

Yeah thanks. 3 days too late :) - I learnt the hard way.