Built Storage boxes for the rear and lightbar for the front

Gris · **Posted:** Thu Jan 04, 2007 10:48 pm

I just finished a few projects.

First was a light bar to hold my ghetto eBay fog lights.

I used some 1.5 angle iron and 2" flat iron. Cut the flat iron to the shape of the "drop" in the early model bumpers and welded the angle iron across them. I used super-short (about 1" long) metal "hollow wall" anchors to hold it in place.

Then I got bored and decided to organize the cargo area. I built some storage boxes out of 1/2" particleboard to store all my crap and to house my air setup. I ran out of carpet, but it makes it easier to see the division and how it matches the split in the back seats. The hole that you see in the right-side box in the first picture is where the air compressor intake filter will protrude.

The Storage box

The Air Box

2006KJSPORT4x4 · **Posted:** Thu Jan 04, 2007 11:34 pm

I'm really liking that box Gris...been thinking about making one myself for my Jeep...or maybe a metal one with drawers and super secret compartment below the drawers for important stuff (what yet i don't know)...but ideas nonetheless....great work...thanks for sharing...

tommudd · **Posted:** Fri Jan 05, 2007 12:32 am

Good job on the light bar and boxes. Light bar will work good, looks good and easy to build.

Jeepjeepster · **Posted:** Sat Jan 13, 2007 4:00 pm

That is awesome! Love the compressor set-up!

What all do you use it for? Just to air up and down? Or do you have Air lockers.

Gris · **Posted:** Sat Jan 13, 2007 6:31 pm

Thanks guys.

ATM, the air does nothing. I am going to finish the actual wiring tomorrow. When done, it will used for tires, and the ARB that is getting installed IN THREE DAYS!!!

jason thompson · **Posted:** Sat Jan 13, 2007 7:45 pm

Gris wrote:

Thanks guys.

ATM, the air does nothing. I am going to finish the actual wiring tomorrow. When done, it will used for tires, and the ARB that is getting installed IN THREE DAYS!!!

some notes on the air if you care
when I did mine I had 1 compresor for lockers and for tires and no matter how hard I tryed leaks leaks leaks
I would fix one and the next time I when out I would find another now keep in mind I went all out with fittings in the front and rear for the air hose along with the lockers so a lot of fittings and hoses running around
I have now pulled out all that fancy crap and kept it simple with the small ARB compressor ,$150 job, and the big one for tires ect.
I also got rid of the 120psi pressure swich and got one for an airbrush setup 40psi max
no air tools but also no leaks and I can air up tires for days cause the compressor dont get real hot at that low psi
I have the tank in the rear right by the compressor and the 1 and only fitting right there with the hose that stays in it wrks like a champ

I would say to keep it simple that is what works

sandracer · **Posted:** Sun Jan 14, 2007 12:50 pm

Nice job on the boxes. I've been planning a set myself. I like the way you matched up with the seat split. I'll have to see just how far my metal detector will collapse down and see if I can utilize the split, too.

I was planning on using 1/2 inch plywood, only because I have a couple sheets left over from setting up the shop. Instead of carpet, I thought I'd try coating the boxes in Herculiner (or similar bedliner).

Gris · **Posted:** Mon Jan 15, 2007 4:38 pm

I always use 1/2" particle board because it's so cheap. But then I end up yelling at myself as I drill ever single hole i need to put a screw in so I don;t split the junk. It's strong enough, but doesn't like being screwed into without a pilot hole.

I used 3 2'x4' pieces total for both boxes, so a single sheet of 4x8 plywood should be more than enough.

sandracer · **Posted:** Mon Jan 15, 2007 5:28 pm

If I didn't already have the plywood, I would have used particle board, as well. I couldn't find any "affordable" bedliner that wasn't black so I'm going to use some left over carpet from the house, instead. One section of the box is just about done. Just waiting for the glue to dry.

Did you chisel out the area for the recessed pulls or just use a hole saw or ? I keep telling the wife I need a router but she doesn't seem to hear me.

Gris · **Posted:** Mon Jan 15, 2007 7:07 pm

I used a hole saw of the appropriate diameter for the main hole. The actual round handle part had tabs that hold it into the metal base piece. I used a dremel & sideways drill bit to notch out the grooves for those tabs.

sandracer · **Posted:** Mon Jan 15, 2007 7:26 pm

Thanks Gris. Guess I'll go back to Ace and snag a pair. But you didn't help in my argument (begging) for a router.

Big D · **Joined:** Mon Jun 05, 2006 10:08 pm **Posts:** 349

Nice setup. I really like the box setup. Are the boxes very heavy? and it's amazing how much the rear tailgate trim panel intrudes into the compartment.

Gris · **Posted:** Tue Jan 16, 2007 1:59 pm

not that heavy. The big one is about 30 lbs but that includes the compressor and tank. The box itself wasn't that heavy, but I didn't weight it at all.

sandracer · **Posted:** Mon Feb 26, 2007 2:27 pm

Thanks for the idea and the motivation. Finally got mine done.

My air bottle will have to live on top when we go out as it was too large to build in to the boxes and I'm too cheap to get another one.

Gris · **Posted:** Mon Feb 26, 2007 7:09 pm

They came out nice sandracer!

I like you clasps. bet that stops any rattle from the lid

sandracer · **Posted:** Mon Feb 26, 2007 8:16 pm

Thanks. The latches were more of a neccessity. I used some plywood that I had left over from setting up the shop and it had warped. Working with warped lumber was a bit of a pain but, hey, it was already paid for. I still need to straighten out one of the latches, though.

Fulltimer · **Posted:** Tue Mar 13, 2007 5:18 pm

"I like the way you matched up with the seat split. I'll have to see just how far my metal detector will collapse down and see if I can utilize the split, too."

As soon as I saw the picture I was thinking of my metal detectors and stuff. What is the advantage of having the box split?

Terry

Gris · **Posted:** Tue Mar 13, 2007 6:02 pm

Fot me, it was so that I can lower one one rear seat and remove only one box to get longer storage if needed.

Fulltimer · **Posted:** Wed Mar 14, 2007 4:28 am

Thanks, that make sense.

Terry

sandracer · **Posted:** Wed Mar 14, 2007 11:42 am

Well, my metal detector doesn't fit in the box but, everything else does. I considered making it as one box rather than two but thought it would be real awkward to put the box in and to remove it when neccessary so, I went with the split too.

As an added bonus, the extra height of the boxes makes it very convenient for loading groceries. Just, pop open the rear glass and set them in. No need to open the tailgate. The wife really likes that feature.

It sure is nice to have things like jumper cables, tow strap, jack & jack board, compressor, receiver hitch and tools always available but out of sight and out of the way.

Built Storage boxes for the rear and lightbar for the front

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