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KJ Storage System - Units going to WA.
http://www.lostjeeps.com/forum/phpBB3/viewtopic.php?f=93&t=45046		 Page 1 of 3
Author:  Glend [ Thu Jul 16, 2009 12:37 am ]
Post subject:  KJ Storage System - Units going to WA.
Well I am finally getting around to finishing the KJ storage system prototype. I have completed the fitting and base construction (I hate making drawers!). The drawer slides are rated at 45kg and I figure that is ok. The top deck is still off because I need to finish everything inside before I do that. The top deck will be carpeted and have tie down points. The system is secured to the KJ using the original tie downs. BTW the drawers are totally waterproofed with epoxy resin so they can carry wet recovery gear, muddy gumboots, cossies, etc. A fridge slide can go on the deck on the right near the powerpoint. Here are a few pics.

Base in place.

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Deck being fitted.

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Drawers fitted.

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Drawers extend out 500mm on 45kg heavy duty slides.

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Side view, sans deck. You can see the rear cargo bin - which will be accessed by tilting the rear seat forward.

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Author:  Boiler [ Thu Jul 16, 2009 1:03 am ]
Post subject: 
Very good looking unit there, great job!
Author:  stevemcc [ Thu Jul 16, 2009 4:04 am ]
Post subject: 
great looking job - love the epoxy finish a great idea.

How about a battery module ? that could be slotted into one of the side sections they look as though they could take a 100 AH AGM on the side with no problem. An isolator switch under the bonnet for safety then the rest - dual controller, battery and fridge feed culd be in one plug in box.

One big drawer would be a nice option but I think the weight would mean thicker ply to stop it dropping in the middle so I'd say stick with two.

Any plans for a second level or a shelf - I know you don;t have a barrier but if you do its great to lift things up

very neat and tidy makes my alluminim and ply shelf look rough as 20 grit :lol:
Author:  stevemcc [ Thu Jul 16, 2009 4:05 am ]
Post subject: 
great looking job - love the epoxy finish a great idea.

How about a battery module ? that could be slotted into one of the side sections they look as though they could take a 100 AH AGM on the side with no problem. An isolator switch under the bonnet for safety then the rest - dual controller, battery and fridge feed culd be in one plug in box.

One big drawer would be a nice option but I think the weight would mean thicker ply to stop it dropping in the middle so I'd say stick with two.

Any plans for a second level or a shelf - I know you don;t have a barrier but if you do its great to lift things up

very neat and tidy makes my alluminim and ply shelf look rough as 20 grit :lol:
Author:  Jeep_Junkie [ Thu Jul 16, 2009 5:39 am ]
Post subject: 
This is great, i love it. But im jealous! i want one too....You should build them and sell them to hopeless ppl like me who have no building skill whatsoeva :wink:
Author:  cmohr [ Thu Jul 16, 2009 11:58 am ]
Post subject: 
Thats some very nice work ther Glen, I hope you kept the plans as I reckon your about to be inundated with requests...
Author:  mikey [ Fri Jul 17, 2009 9:03 pm ]
Post subject: 
Ok Glenny, old buddy, old mate......

How much for one???? :D :D

Super stuff.
Author:  Glend [ Fri Jul 17, 2009 9:45 pm ]
Post subject: 
More pics coming in the next few days. The Deck is on now and the carpet work will be finished over the weekend.

And yes Mikey, I will be making them to order if there is interest. As to the cost, I need to total up the materials and work out my labour hours before I can come up with a figure (stay tuned).

I'm also thinking of making the plans available for those that want to try DIY.

:D
Author:  mikey [ Fri Jul 17, 2009 10:37 pm ]
Post subject: 
Looking forward to more pics,
Excellent news for a DIY numpty like myself!!!
Thanks mate.
M.
Author:  jeepmedic46 [ Mon Jul 20, 2009 6:16 pm ]
Post subject: 
Looks good, Can't wait to see the pics. :)
Author:  gi frog [ Tue Jul 21, 2009 1:54 am ]
Post subject:  KJ storage
Thats a great design Glen they look good.
You can add me to the list once you start taking orders.
James
Gi Frog
Author:  Glend [ Wed Jul 22, 2009 1:50 am ]
Post subject:  Updated Photos
Here are the updated photos I promised. Just a few little things to finish off: paint the drawer faces, install the handles, put in a centre trim piece between the drawers, and install the tie downs on top of the deck. Notice the stainless steel tie down points for the unit, the two on the side panels attach to the existing rear tie downs in the KJ, the other two are hidden inside the slanted cubby and attach to the front tie downs on the KJ (attach with cam lock straps or small turnbuckles).

Image

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Author:  mikey [ Wed Jul 22, 2009 3:00 am ]
Post subject: 
Very, Very Freakin' Sweet 8) 8)

Ill have mine in Black please!!
Author:  NTJEEP [ Wed Jul 22, 2009 8:48 pm ]
Post subject: 
Top job there! What did you use in the corners to get the rounded effect, tape? as in a bathroom waterproof job?? Or putty?
Nice work Glen.
Author:  Glend [ Wed Jul 22, 2009 10:00 pm ]
Post subject: 
The rounding effect (on internal corners) is due to the epoxy filleting used to bond the entire structure together (aka Stitch and Glue boatbuilding method). The external corners are routed with a rounding bit and then fibreglass taped. This approach makes the entire structure a one-piece monocoque and very strong.

http://en.wikipedia.org/wiki/Monocoque


The deck has router rounded edges and the marine carpet is glued with a contact adhesive and wrapped around the rounded edges and fastened to the underneath of the deck with glue and industrial staples.

All of this and more will be in the plans.
Author:  stevemcc [ Thu Jul 23, 2009 3:27 am ]
Post subject: 
Great finshed product love the attention to detail all the way through. I know you've been thinking about plans and finished products - any thoughts on flat pack kits - would make shipping cheaper ?
Author:  Glend [ Thu Jul 23, 2009 4:58 am ]
Post subject: 
Steven, yeah I could do a flat pack kit. Cut it all out and drill the holes for the cable ties to stitch it together. Due to the one piece deck it would be outside of the dimension limits for Australia Post Parcel Post but there would be other options for delivery (like couriers: TNT, etc). BTW I weighed it today (finally finished) and it came in at 23kg which is not to bad. I think I could get the weigh down a kilo or two. The 45kg rated drawer slides that I used are heavy and weight could be saved there by going down to 20kg rated slides (that's probably enough for many people).
Author:  nobster [ Thu Jul 23, 2009 5:41 am ]
Post subject:  rear draws
Looking great there Glend, any pic's of finished product
Author:  pipeliner [ Thu Jul 23, 2009 5:47 pm ]
Post subject: 
How much more finished do you want it Nobby?

Oh, I see, you mean installed!
Author:  mikey [ Thu Jul 23, 2009 5:54 pm ]
Post subject: 
Glen,
If you need someone to test the prototype, I'm off to Fraser next weekend, so I'd be happy to put it through it's paces :wink: :wink:
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