Home made side locker fitted to a 110.

[alien]

After spoting a side locker at a SLoW event I got talking to the owner, as you do.
He had a spare box with no lid and offered it to me at a acceptable price.
AULRO courier service got it to me in Vic. from QLD..
I sourced hatch cover rather than make one from checker plate or similar.
Access Hatch, suits hole 205mm x 305mm, PVC, White With Lock and Handle | Caravan Access Doors | CaravansPlus


Dimensions of the box are...365Wx302Hx332D with a 30mm folded lip.
This gave me a 6mm gap to take up on a 2011 (MY12) 110 variant.
This box has an internal lip, most aftermarket units have external lips that use a large door cover.

Stage 1, making the space to fit it.
Removed and discarded panel brace after removing 1/2 the draw system to access the bolt head.
Place back corner on axle stand and remove wheel and mudflap.
I needed to cut out a gusset from the wheel arch, take a corner off a chassis brace and modify the rear exhaust mount to make room.
I also converted the reverse light mount as it has nuts on the rear only accessible from the rear behind a plastic infill panel, 2 rivnuts and now bolted from the lens side.
I also had to fit rivnuts to my shelf/draw wing mount.
There was also a bolt I removed and fitted a rubber grommet to the hole, suspect it's a seatbelt mount?



Stage 2, Fit and bolt in.
After getting the box in the hole for the 8th time it was time to cut the panel.
Care is needed so as not to crease the 1/4 panel due to the flex required to maneuverer the box in and out for trial fitting.
I marked where the box lip was and door was to be placed.
I then cut a hole smaller than required but big enough for the drill to fit.
I then mounted a angle bracket on the inner upper corner with matching flat plate on the inside of wheel arch.
To fill the gap where the step of the arch is I found a 50mm square gall off cut.
This had the box opening parallel to the 1/4 panel, be it with the expected gap after measuring before committing myself to the job.
Again I have flat plates both inside the box and over the arch.
This should put all the weight on the mounts and not the 1/4 panel.


Stage 3, fit door and bolts up the outer panel.
With the box bolted tight to the wheel arch I had a 6mm gap that I put some flat alloy strips into.
I then remarked and cut the opening for the locker door now I had worked out where I wanted it.
The row of bolts is to hold the lower edge of the box to the panel.
The hatch is then screwed on to sandwich the 1/4 panel between it and the box.
*I need to remove and refit the hatch as I've used the wrong salastic on it.



More pictures to follow, again no set order.
Attached Thumbnails

[alien]

If you have any questions please ask.


More pictures...

[weeds]

Nice work......I looked at the plastic doors when I did mine (converting existing open box and a poorly sealed box) but could find one the right size.

I see Daniel from Mulgo does one where from memory the doors doesn't protrude all that much from the body work. I agree the mass produced version does have a bulky door.

[Tombie]

Nice work Kyle.

[Surrufus]

Looks great!
There is no way I'd be game enought to cut a hole that big in Alice.

[alien]

Looks great!
There is no way I'd be game enought to cut a hole that big in Alice.

The hole is lot smaller than some of the lockers available...
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