PCH's D3 rear cargo box

[PCH]

I've been busy in my garage at home and have been building my rear cargo box - what do you think?
The design contains the following:

1. Easy to remove and fit - I can lift it in by myself when I take the draws out. It is bolted in using the 4 tiedown points in the rear and I use 2 ratchet straps to secure the box to the tiedown points.

2. From the rear you access the fridge and 2 draws. The lower draw fits the Tirfor winch and recovery straps, toolbox, jacking plate and shackles which are strapped into the draw. Beneath the lower draw I store the 20m steel cable and snatch block. The upper draw is for the ARB air compressor, gas cartidges for the stove/water heater and other camping stuff. The draws slide on 20mm angles and with silicon spray they slide quite well with the weight of the winch and tools. Above the fridge I slide in a folding table complete with stools.

3. In front of the box there is a place for the water heater, 20lt of water and a deep cycle battery.

4. Above the cargo box there is another box (not shown) which bolts to the main cargo box which holds the stove and food containers. Next to this box is storage space for clothing bags which are strapped down.

Qubeloc frame in the D3 takes up the whole rear cargo area
http://www.aulro.com/albums/album260/DSCN1433a.jpg

Qubeloc frame before ply sheeting and carpet
http://www.aulro.com/albums/album260/DSCN1441a.jpg

Rear view of fridge slide
http://www.aulro.com/albums/album260/DSCN1466a.jpg

Upper draw
http://www.aulro.com/albums/album260/DSCN1465a.jpg

Chris

[hiline]

my oh my pch you have been busy style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

well done mate :wink:

[wardy1]

Well done Chris, looks great..... when are you coming over to make one for my D2? style_emoticons/<#EMO_DIR#>/laugh.gif
Seriously though, you mentioned that the drawers run on angle with silicon spray....no drawer runners? Just be interesting to see if they bind up when things get excessively hot or cold (expansion/contraction)
Roughly how much did your set up cost please?

[PCH]

Wardy,

I spent about $800 on the materials and fridge slide. Aluminium with plastic connectors was $200, slide was $270, ply/carpet/hardware $330. If I used slides for the draws I reckon they would have cost at least another $200 for four.

Time taken was about 2 weekends and most week nights in between.

I don't reckon the expansion of the aluminium will bind as there is at least 1-2mm free play in the draws. The quebeloc stuff is very ridged when knocked together plus when you ply sheet it with self tappers it aint going to flex much anymore.

Chris

[George130]

You have been busy. Maybe I should finnish my rear spotlights :oops:

[rmp]

Where did you get this Quebeloc stuff from?

thanks

[WOLLAPIT85]

Qubeloc: Capral Aluminium (bayswater, Clayton, Preston, Dandenong, Sunshine)

Or Smart Aluminium (Dandenong, Airport West Tomasstown, Bayswater, Laverton Nth) has same called Smartlok joiners

[DiscoTDI]

Looks great 8)

did you lose much skin making that :twisted:

[PCH]

As Wollopit85 said it is from Capral.

The proper spelling is Qubelok (I was spelling it incorrectly).

http://www.capral.com.au/capral/_product_d...eTitle=Products (http://www.capral.com.au/capral/_product_detail.jsp?id=6&product=2&user=8&PageName=Other%20Products%20:%20Qubelok&PageTitle=Products)

I bought it from the Capral store on Dandenong Road - Clayton. They did delivery FOC and they had to do it twice because they got the 20mm angle wrong style_emoticons/<#EMO_DIR#>/laugh.gif style_emoticons/<#EMO_DIR#>/laugh.gif

The 25.4mm square tube has a wall thickness of 1.6mm and it come in lengths of 6.5m and are around $24 each and the joiners are about $1.50 each.

Chris

[Ace]

Thats an awsome set up, you could make so dough selling them. Matt

[seqfisho]

Originally posted by PCH
If I used slides for the draws I reckon they would have cost at least another $200 for four.



I don't reckon the expansion of the aluminium will bind as there is at least 1-2mm free play in the draws.

Chris

So what did you use for the drawers to run on and how did you prevent them from completely coming out/being pulled too far out :?:

I have been thinking about the qubelok since I saw Drivesafes setup but was only going to do a pair of drawers across the floor as per Outback and Black Widow style as I have to fit the engle (40lt ) sideways due to space restrictions (S1 Disco) style_emoticons/<#EMO_DIR#>/sad.gif

[matbor]

Originally posted by seqfisho

Outback and Black Widow style as I have to fit the engle (40lt ) sideways due to space restrictions (S1 Disco) style_emoticons/<#EMO_DIR#>/sad.gif

Take the metal handles off and I made up webbing style handles to use to tie it down, just as strong.... If you have a cargo barrier it's a different story though style_emoticons/<#EMO_DIR#>/smile.gif

Matt.

[PCH]

Originally posted by seqfisho+--><div class='quotetop'>QUOTE(seqfisho)</div><div class='quotemain'><!--QuoteBegin-PCH
If I used slides for the draws I reckon they would have cost at least another $200 for four.

Chris

So what did you use for the drawers to run on and how did you prevent them from completely coming out/being pulled too far out :?:

style_emoticons/<#EMO_DIR#>/sad.gif[/b][/quote]

For the draw slides they are primitive - They are 20*20*3mm aluminium angle which has been screwed to the Qubelok. The Qubelok slides in the angle and with a bit of clearance 1-2mm and silicon spray they seem to slide smoothly with the weight of a T516 tirfor, recovery straps, shackles and toolbox. The draw might weigh 40kg with this in it and it still slides okay. I didn't make anything special to limit the draw falling out since I think it has sufficient friction even on a steep hill that won't let the draw slide out by itself. When the draw is closed I use a window deadlock to keep it closed.

Hope that helps.

The Qubelok (or similar) is really easy to work with as long as you have a dropsaw with aluminium blade. I used my brother's $68 GMC dropsaw.

Chris

[seqfisho]

Originally posted by matbor+--><div class='quotetop'>QUOTE(matbor)</div><div class='quotemain'><!--QuoteBegin-seqfisho

Outback and Black Widow style as I have to fit the engle (40lt ) sideways due to space restrictions (S1 Disco) style_emoticons/<#EMO_DIR#>/sad.gif

If you have a cargo barrier it's a different story though style_emoticons/<#EMO_DIR#>/smile.gif

Matt.[/b][/quote]

:cry: :cry: :cry: you guessed it :cry: :cry: :cry:

[seqfisho]

Originally posted by PCH+--><div class='quotetop'>QUOTE(PCH)</div><div class='quotemain'>
Originally posted by seqfisho@
<!--QuoteBegin-PCH
If I used slides for the draws I reckon they would have cost at least another $200 for four.

Chris

So what did you use for the drawers to run on and how did you prevent them from completely coming out/being pulled too far out :?:

style_emoticons/<#EMO_DIR#>/sad.gif

For the draw slides they are primitive - They are 20*20*3mm aluminium angle which has been screwed to the Qubelok. The Qubelok slides in the angle and with a bit of clearance 1-2mm and silicon spray they seem to slide smoothly with the weight of a T516 tirfor, recovery straps, shackles and toolbox. The draw might weigh 40kg with this in it and it still slides okay. I didn't make anything special to limit the draw falling out since I think it has sufficient friction even on a steep hill that won't let the draw slide out by itself. When the draw is closed I use a window deadlock to keep it closed.

Hope that helps.

The Qubelok (or similar) is really easy to work with as long as you have a dropsaw with aluminium blade. I used my brother's $68 GMC dropsaw.

Chris[/b][/quote]

Ahh, you also used the qubelok for the drawers themselves and just put ply panels on the sides etc, so the qubelok tube frame is what slides on the angle, am I correct :?:

[matbor]

Originally posted by seqfisho+--><div class='quotetop'>QUOTE(seqfisho)</div><div class='quotemain'>
Originally posted by matbor@
<!--QuoteBegin-seqfisho

Outback and Black Widow style as I have to fit the engle (40lt ) sideways due to space restrictions (S1 Disco) style_emoticons/<#EMO_DIR#>/sad.gif

If you have a cargo barrier it's a different story though style_emoticons/<#EMO_DIR#>/smile.gif

Matt.

:cry: :cry: :cry: you guessed it :cry: :cry: :cry:[/b][/quote]

Get the angle grinder out then style_emoticons/<#EMO_DIR#>/smile.gif

Out of interest is it a full height one or half height one :?: as I'm looking at getting a half height one but I think I might have to cut into it style_emoticons/<#EMO_DIR#>/sad.gif like what gidget did to his :cry: http://www.aulro.com/modules.php?name=Foru...p=104736#104736 (http://www.aulro.com/modules.php?name=Forums&file=viewtopic&p=104736#104736)

Matt.

[seqfisho]

Originally posted by matbor+--><div class='quotetop'>QUOTE(matbor)</div><div class='quotemain'>
Originally posted by seqfisho+--><div class='quotetop'>QUOTE(seqfisho)</div><div class='quotemain'><!--QuoteBegin-matbor@
<!--QuoteBegin-seqfisho

Outback and Black Widow style as I have to fit the engle (40lt ) sideways due to space restrictions (S1 Disco) style_emoticons/<#EMO_DIR#>/sad.gif

If you have a cargo barrier it's a different story though style_emoticons/<#EMO_DIR#>/smile.gif

Matt.

:cry: :cry: :cry: you guessed it :cry: :cry: :cry:[/b][/quote]

Get the angle grinder out then style_emoticons/<#EMO_DIR#>/smile.gif

Out of interest is it a full height one or half height one :?: as I'm looking at getting a half height one but I think I might have to cut into it style_emoticons/<#EMO_DIR#>/sad.gif like what gidget did to his 8O http://www.aulro.com/modules.php?name=Foru...iewtopic&t=7250 (http://www.aulro.com/modules.php?name=Forums&file=viewtopic&t=7250)

Matt.[/b][/quote]

Its a full height unit and I wont be cutting into it just yet 8O

I tried the fit without the handles on at the height I would have the drawers and it is still about 2" too long to go longways, so will look at making a sideways slide to sit on the drawers.

I will only be making the drawers about as high as the wheeel arches, that should still provide plenty of storage and retain a flat rear load space for day to day needs (shopping etc) as I had a full blown drawer system in my Pajero and although it was great when away it was a pain most other times as it took up 75% of the cargo space 8O which also meant alot of extra weight getting dragged around all of the time style_emoticons/<#EMO_DIR#>/sad.gif

[MickG]

Originally posted by PCH
I don't reckon the expansion of the aluminium will bind as there is at least 1-2mm free play in the draws. The quebeloc stuff is very ridged when knocked together plus when you ply sheet it with self tappers it aint going to flex much anymore.

Chris

Great looking set up Chris, I know a few people who have used the Qubelok. I currently have a home made system (made by someone else) which relies on silicon spray on the aluminium runners and I find it does get real stiff real quick when loaded up :roll: - I carry a hand winch, cable, shackles, silicon spray etc in one drawer. The other drawer is not to bad but I am now looking into modding the system to run on some kind of bearing system, the problem I have though is only about 1-2 play, so the router is going to have to be used to create some hollows somewhere - thinking of putting a few on the bottom somehow :?: .

Anyway, looks good and keep us posted with any more mods to the system.

Aye, Mick

[PCH]

Originally posted by seqfisho+--><div class='quotetop'>QUOTE(seqfisho)</div><div class='quotemain'>
Originally posted by PCH+--><div class='quotetop'>QUOTE(PCH)</div><div class='quotemain'><!--QuoteBegin-seqfisho@
<!--QuoteBegin-PCH
If I used slides for the draws I reckon they would have cost at least another $200 for four.

Chris

So what did you use for the drawers to run on and how did you prevent them from completely coming out/being pulled too far out :?:

style_emoticons/<#EMO_DIR#>/sad.gif

For the draw slides they are primitive - They are 20*20*3mm aluminium angle which has been screwed to the Qubelok. The Qubelok slides in the angle and with a bit of clearance 1-2mm and silicon spray they seem to slide smoothly with the weight of a T516 tirfor, recovery straps, shackles and toolbox. The draw might weigh 40kg with this in it and it still slides okay. I didn't make anything special to limit the draw falling out since I think it has sufficient friction even on a steep hill that won't let the draw slide out by itself. When the draw is closed I use a window deadlock to keep it closed.

Hope that helps.

The Qubelok (or similar) is really easy to work with as long as you have a dropsaw with aluminium blade. I used my brother's $68 GMC dropsaw.

Chris[/b][/quote]

Ahh, you also used the qubelok for the drawers themselves and just put ply panels on the sides etc, so the qubelok tube frame is what slides on the angle, am I correct :?:[/b][/quote]

Yes, that's right I sheet the Qubelok draw frame with ply. For the base of the draw I use 12mm ply.

Chris