JK secure cargo area build
04-21-2009, 03:51 PM
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JK secure cargo area build
Inspired by a few other builds by others I decided to build a "cargo cover" for my JKs cargo area. The goals were to be able store stuff "securely", have the top deck be usable (not done yet), look half-way decent (ie not look like crap) and not interfere with either the soft or hard tops. A few pictures / comments:
I didn't get any earlier pics but I basically used large pieces of cardboard and cut out templates until the fit was good. Then I transfered the shaped to some 5/8" plywood, cut it out, sanded the edges and painted with some nice (cheap) barn red paint. Here are the pieces installed:
Another view showing some of the cut outs:
Behind the seats:
I don't have the tools/knowledge for much metal work so the frame is made out of wood and is beefy enough to hold any weight put on top of the deck. It can't all be seen but there is a piece of angle iron running across the middle with custom "feet" catching the lip of the tub on each side. That plus small pieces in each corner (with the same "feet") keep the box from coming (or being lifted) out. A view of the inside:
Finally, put some cargo carpet (from Wal-Mart) down over the wood (what a pain in the butt):
All told I have about $60-80 into it at the moment. I have a cargo rack ordered that I plan on mounting on top of the deck to put stuff in (and tie down to). All in all I'm happy with it. If the carpet doesn't hold up I might try to herculine it at some point.
If I were to do it all over again I would probably try to minimize the internal frame - try to keep it all high up on the wheel wells. Regardless, I love being able to stop at the store and not having to worry about stuff that I've tucked down on the floor (or lugging it around with me).
I didn't get any earlier pics but I basically used large pieces of cardboard and cut out templates until the fit was good. Then I transfered the shaped to some 5/8" plywood, cut it out, sanded the edges and painted with some nice (cheap) barn red paint. Here are the pieces installed:
Another view showing some of the cut outs:
Behind the seats:
I don't have the tools/knowledge for much metal work so the frame is made out of wood and is beefy enough to hold any weight put on top of the deck. It can't all be seen but there is a piece of angle iron running across the middle with custom "feet" catching the lip of the tub on each side. That plus small pieces in each corner (with the same "feet") keep the box from coming (or being lifted) out. A view of the inside:
Finally, put some cargo carpet (from Wal-Mart) down over the wood (what a pain in the butt):
All told I have about $60-80 into it at the moment. I have a cargo rack ordered that I plan on mounting on top of the deck to put stuff in (and tie down to). All in all I'm happy with it. If the carpet doesn't hold up I might try to herculine it at some point.
If I were to do it all over again I would probably try to minimize the internal frame - try to keep it all high up on the wheel wells. Regardless, I love being able to stop at the store and not having to worry about stuff that I've tucked down on the floor (or lugging it around with me).
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04-21-2009, 05:29 PM
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Plywood: The top deck is made out of two pieces - each piece has 'half" of the required cut out for the rollbar/seatbelt mechinism and they clamp together (kind of like medieval stocks). This picture shows the seam (circled in yellow):
Carpet: The carpet is one piece for the top deck with the hole for rollbar/seatbelt cut out and a cut from that hole out to the edge. The one visible mistake is that I messed up the cut on the drivers side so there is small square patch (which is visible). The passenger side came out like it was supposed to and you can't see the seem unless you look specifically for it.
Carpet: The carpet is one piece for the top deck with the hole for rollbar/seatbelt cut out and a cut from that hole out to the edge. The one visible mistake is that I messed up the cut on the drivers side so there is small square patch (which is visible). The passenger side came out like it was supposed to and you can't see the seem unless you look specifically for it.