1) Not expensive
2) Modular, so I can adjust it to suit my needs on the day
3) Fully removable
4) Sturdy
5) Simple to use
6) doesnt waste space
7) wont require heavy modificaton of the tray or canopy.
8) not too heavy
So big heavy permanent drawer systems on runners are out.
In my old BT-50 I made up something pretty simple, but it was slightly cumbersome at times and designed to allow me and the missus to sleep on it with gear underneath. Not a requirement now as we've now got my young son on the scene, so this is what I've come up with. Its only phase one, so more to come in the next few weeks.
Bought a single piece of 1800mm x 1200mm concrete forming 18mm ply. I chose concrete forming ply over standard outdoor or marine ply because it was cheaper, apparently a bit stronger, and coated in a nice slick black paint thats more like 2 pack or something tough. Must be to allow tradies to make concrete walls with it and re-use the stuff again.
My Ironman canopy is made of the tough 9mm ABS plastic (same as Carry Boy), and covered in carpet. There is an inch wide lip where it sits on the ute tub, which give me a good solid platform to work with.
The side folding windows also allow me to slide large items into place without having to worry about leaning over the tailgate and manouvering big slabs of timber in.
I cut out a 1470 x 1200 piece, then cut that into 3 even pieces of 1470 x 400. Starting with the piece closest to the cabin, I slid it up to the cabin, marked the curved corners so I can trim it to match the contours of the canopy, and marked where bolts from the canopy brackets stick up. I drilled out the holes for the bracket bolts, belt sanded away some space for the bracket as well and trimmed hte corners. Now it sits flush up against the cabin.
Middle piece just sits in place well, and doesnt need to accomodate any bolts or brackets on the canopy lip. The rear one closest to the tailgate has been drilled and sanded for another pair of brackets. The bolts sticking up through the holes stops the panels from moving, and brace it all nicely together.
So phase one of the project I now have a modular, light weight, 3 piece shelf I can use to make better use of the canopy space. Heavier stuff will go underneath on the tub, and lighter bulky stuff on top. I can just fit 1, 2 or 3 pieces of the top shelf, in case I have something particularly large, which will go towards the back.
Phase 2 will go something like this:
Add carpet to the tops of the 3 panels, to reduce items moving around. That black paint is pretty slick.
I'll build 2 long skinny boxes, that will encase the wheel arches, but extend all the way to the back of the canopy to the tailgate. I'll build in separators inside, and flip top lids, creating space for things like dual battery, water bladder, recovery gear, tools, etc. As there is a decent space above the wheel arches and below the shelf, there will be room to flip the lids up should I need. Not sure how I'll fix them in, but i have a factory tub liner I could screw into for bracing.
On the tub floor, I'll cut another single sheet of 18mm ply, and cut it to match the entire space between the 2 wheel arch boxes, front of the canopy, and back to the tailgate end. I'll add a handle, so when I drop the tailgate, I can pull the ply floor sheet out, giving me access to everything stored toward the front. I'll probably build a wall at the front end, so things dont slide off when I pull the base out. If need be I'll add extra walls and separators to make compartments. Might leave one side open, and compartments on the other side.
I may even split the base panel into 2, and make 2 separate, open top sliding drawers, if 1 single piece feels too big or heavy. I'll also add a folding leg of some sort, so I can slide it past the tailgate if need be, and it can be supported on the ground.
I've seen a couple of setups with some of these characteristics before, so hopefully I can meld it all together and make it workable and tick all my priority boxes.
More photos to come !
Here's the system from my old BT-50
