Going offroad into deep woods or on extended weekend
trips sometimes requires a stay of overnight, or several nights.
Many times we have a cabin to sleep in. Sometimes not. Tents
are ok but offer little protection from the 700 lb black bears that roam
the mountains where we 4 wheel. If it's possible, sleeping in an
enclosed vehicle is ideal. The FJ Cruiser has a fair amount of
interior room and when you fold down the rear seats and slide the front
seats forward, the area becomes even greater. The only problem is
this area is not flat. The rear seats do not fold down completely flat and
the seat part of the rear seats is about 12 inch up above the rearmost
floor. The back of the rear seat becomes a ramp going up on an
angle. The only way to get a flat area is to create an elevated
platform. By elevating a platform, you can get about 72" from the
back of the front seats to rear door at about 42" to 52" wide depending on
where you measure. So I set out to make a platform.
The main goals of this project were:
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To make a sleeping area long enough to
stretch out my 5"10" body.
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Not require the removal of anything
structural like the rear seats, which I want to be able to use easily.
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Allow the platform to be quickly and
easily broken down and the rear seats be brought back up.
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The platform had to double as storage
area since it will be occupying my cargo area.
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Everything necessary to make this
platform work had to be stashable back into the main section of the
platform.
I sketched up several designs and look at
several platforms other FJ owners had designed. I finally came up
with a simple yet very effective design that fit nicely in the rear cargo
area and sat no higher than 11 inches tall, yet yielded a 72" x 42"
platform and provided two lockable 28" x 20" slide out cargo drawers.
The structure also allows access to my 110V AC outlet in it's original
location, is secured down tightly to the floor of the FJ, allows the rear
seats to fold up unrestricted and is easily removable if desired. On
top of that, when it is completely stashed in it's compact position, it
appears to be part of the FJ's structure. Here's the details on how
I made this Platform / Cargo Box:
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The first thing was to decide how tall to make this
platform. I looked at the interior and decided that I did not want
to be higher than the fender wells for several reasons. One, I need
head room. Two, I didn't want to be too high for placing items on
top of the cargo box nor did I want to cover my sub woofer speaker.
Three pieces of 2x10 sections at 28" long did the trick. Three for
structural integrity. Not too heavy but strong. 28" long put
it right between the forward side ramp and allowed the rear do to close. |
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The 110 volt AC outlet would be right behind the passenger
side upright. I thought about insetting this piece but then I'd be
wasting cargo space. Instead I decided to make a cutout, accessible from
the top with a hatch and down through the cargo drawer. |
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The other side has the stock jack storage area. Since
this storage area yielded little cargo space, I decided to forget about it
and cover it up. I carry a better bottle jack so I'll leave it in
there for emergency backup. IC an get to it if I remove the storage
box. |
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Next step was to secure these 2x10's to 1/2" plywood top
and bottom. The plywood pieces are 28 x 42". 42" is the width
from fender well to fender well. I used 2" course thread drywall
screws. |
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Here is a test fit of the Cargo Box. |
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Outlet accessibility. |
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After a test fit, I determined that if I rounded the
corners, I would one, make it easier to put in and take out, but two it
would fit better in the FJ's cargo area. So I took a belt sander to
all the edges and gave them a nice rounded edge. This will also
allow me to wrap the box more cleanly with the black carpet material
later. |
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Below is the side that faces the seats. A 2x3 with 15
degree angles was secured to the side, 1/2" below the surface of the
plywood. My platform will rest on and be secured to this 2x3.
I'll also use this 2x3 to secure the box down to the forward most
tie-downs in the FJ using turnbuckles and eye hooks. |
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The rear side of the cargo box will be secured to the stock
tie-down bolt holes, which I'll remove and relocated on top of the cargo
box.
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To secure the storage box to the floor, I put two eye hooks
in the front facing 2x3. These eye hooks will be located right above
the stock tie-down in the bed of the FJ. The rear of the storage box
will be secured by drilling through the bottom piece of plywood and
bolting it down into the now removed tie-down points in the floor.
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To gain access to my 110V power inverter outlet, I added a
hatch just above the inverter outlet in the FJ. I already have an
access opening in the side of the storage box and I will put an opening in
the side of the drawer as well. So to get to the plug, I put this
handy hatch in the top. I installed the hinge on the outlet side so
it swings up and towards the passenger side.
Below to the right shows the carved out inset in the
wood for the hinge.
Further below are pictures of the simple method for
stopping the door from swinging down too far. I screwed a large
washer to the corners to act as a stop for the door. The sharp tip
of the screw will get cut off. Works like a charm. |
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Below is the platform folded in half. Each piece of
1/2 plywood is 42" wide by 21 1/2" long. A long hinge is used to
secure the two pieces of plywood together. When open in the vehicle,
the one end of the plywood platform will bolt to the 2x3. The bolts
are only hand tightened to hold it in place, allowing for a quick removal.
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Below is an application of semi-gloss latex paint in all
the areas where the black carpet material won't cover.
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Carpet Time A trip to Home
Depot and I bought a 5x7 roll of high traffic gray / black low matte
carpet. This matched the FJ's interior pretty well and was very
similar to the center section of the seats. I used 1/2" staples to
secure the carpet to the plywood.
The cut sides of the carpet got a light coating of
rubber cement to keep them from fraying. That worked out quite well.
For the Power inverter hatch, carpeted over that, then
used a sharp utility knife to cut into the gap and free up the hatch.
I then glued the carpet down to the hatch. I also added a short
strip of nylon strap and glued to the underside of the hatch so I had
something to grab when I need to open the hatch. The glue called
"Goop" works really well for this as well as a large variety of other
purposes. Goop secures anything to anything else. I always
have a supply. |
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Securing the Storage Platform Down
The entire storage platform has to be secured to the bed of
the FJ. This was quite easy. I took advantage of the four
tie-down spots in the FJ. The forward two on the floor, I use two
turn-buckles. For the rear two tie-down locations, I removed the
tie-downs and used longer metric bolts and a washer to secure the
platform.
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Support For The Folding Platform
Three 6 3/4" dowel rods, three studs (wood threads on one
side, 7/16" threaded on the other), three rubber feet, and three metal
thread counter-sinks (or what ever you call them). The dowel rods
were attached just behind the hinge, one on center and the other two 6
inches in from the sides. This give the necessary support for the
weight of an adult on the platform. |
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Modifying the CB Mount for Quick Dis-Connect
My CB is installed in the passenger's lag area on the right
side of the center console. This is a very handy area for the CB to
be when I use the CB, however my
original method of attaching the CB
did not allow it to be easily removed and re-attached. Removal was
going to be necessary when the front seats are slid completely forward to
gain as much room as possible for the sleeping platform. So I had to
re-think the CB hanger. At first I didn't want to drill a hole in
the console to mount the CB but now that I've had it there for a few
months, it going to remain in place. So here goes the drilling.
I discovered that I could easily pop the transfer case shift lever's boot
out to gain access to the interior of the center console. That made
it easy to drill out a hole in the right place since I can see nothing is
in the way. Now I can get a bolt in there. With the right size
bolt, one washer and nut followed by the CB bracket, a pair of wing nuts
can easily be used. Now the CB is easily removed by hand when the
seat has to go fully forward.
Wing-nuts easily removed
leaving just the bolts, the
seat easily clears the bolts. |
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I Transferred the OEM tie downs
to the top of the Storage Platform |
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Next was to put the carpet over the two pieces of 42" x 21
1/2" x 1/2" plywood. They are already connected with the long hinge
at this point and painted. I started off with placing each side over
the carpet as it lay upside down on the work bench and I traced and marked
the pieces. Then using a straight edge as a guide, cut them with a
sharp utility knife. Each side was stapled down securely. I
later did a little trimming to get a nice clean edge. Again, all the
cut sides were lightly covered with a layer of rubber cement to keep them
from fraying. Below: I had to open up the bolt
holes again so I used a blow torch and heated up a 12 penny nail.
Pressing it through the hole, it melted the carpet nicely, opening up the
hole. |
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Drawer Fabrication
The two drawers measure 28" deep x 20" wide x 9" tall,
a considerable amount of storage area for the vehicle.
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Drawer installed, hardware below. |
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Overall thoughts after a weekend of
camping and 4-wheeling. Great Mod! The
storage is great. All of my recover gear, tools and a portion of my
supplies are stashed in these drawers with room to spare.
Sleeping in the back of the FJ was comfortable! I
had an air mattress that was the right length and not too wide as to allow
me to stash my gear next to me while I slept.
Thinking ahead, I'll probably make a few adjustments to
create a multipurpose configuration to the platform that might allow me to
have it setup yet be able to drive the FJ. Maybe by adding another
hinge to the forward most section of the platform. But for now, this
was great. I could stretch out, relax and get a good night sleep
while stashing my gear below. This was the purpose of the project
and it accomplished that with flying colors.
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