Bug Out Box Build

[Hondarider]

First off...this is not much of a build thread...mostly because I forgot to take pictures while I was building it. It was just a one day type of fun project and the end results are certainly nothing spectacular, but I usually take pictures of everything. I dropped the ball on this...so all I can show you is the finished product and provide some narration on the design rationale. I'll do better next time.

Anyhow, as I've chronicled here over the past few months, I took possession of a 2015 Trail at the beginning of the summer and immediately took it in a cross country trek. During the last 3 months and 8000 miles, I have been very happy with the 4Runner, but I noticed one glaring deficiency. There are no discrete storage locations in the back of this thing...no under floor box...no side lockers of any significance...no under-seat trays...virtually nothing.

Now, as an amateur zombie apocalypse prepper and full time Man of Action, there are certain things that I like to keep in my vehicle at all times...jumper cables...socket set...tow strap...first aid kit...Sig 220...100' of rope...zip ties...bottled water...latex gimp suit...fire extinguisher...cash...vice grips...compass...deck of cards...Model 1300 stainless marine...Maglight...energy bars...duct tape...tarp...a USB stick with copies of all personal data...toilet paper...waterproof matches...a samurai sword...the Boy Scout Field Guide...the Pocket Ref...super glue...sewing kit...poncho...Leatherman tool...backpack...ammo...gloves (latex and cold weather)...topo maps...spare batteries...air horn...tweezers...magnifying glass...feminine hygiene products...fake passport...fishing tackle...bolt cutters...pry bar...Excedrin Migraine...wire strippers...notebook...bow saw...a Bill Clinton mask...wool socks...a signed copy of Leanings by Peter Egan...and a bottle of Jagermeister. You know...basic necessities.

 

[calcrc]

Hi man, I have the same survivor issues as you do

I was thinking about making a B.O.B. for the truck thread, nice work.

 

[Hondarider]

As winter approaches and the zombie apocalypse looms with near certainty, I decided that I would need to address my Toyota's storage limitations. I considered a Pelican box, famed for their durability and resistance to the elements, but I couldn't find one that would fit well without monopolizing the entire rear of the vehicle. They're kinda pricey too. I looked at drawer units and overland goodies, but I'm not the type of guy who likes to pay someone else to solve their puzzles.

Instead, I set about constructing my own solution. My goals were somewhat simple. I wanted a lockable storage box which would allow me to take advantage of the available space in the back of the 4Runner, yet still leave room for things like my chain saws, groceries, or the dog behind the rear seats. To that end, I decided the a shallow locker that covered the entire rear cargo area, but provided an elevated version of the floor, would do the trick. Now I know that drawers are handy because they can be accessed even when the cargo area is full to the ceiling, but I feel that the individual drawer bodies and slider mechanisms consume too much of the available storage space...at least if I were building it out of wood. Instead, I'd opt for a hatch type door on top. I'd make my hatch door only half as deep as the box so that I won't have to unload the entire cargo area just to access the box. However, concessions will have to be made; its not perfect. I sized the box to consume the entire carpeted area of the cargo space, but not so deep as to prevent the rear seats from reclining fully...the kids would not be happy. I settled on a height that would allow me to store a 6 pack of bottled water...upright and fully assembled...while creating a surface just about level with the shelves over the wheel wells...leaving only a fraction of an inch space so the dogs feet wouldn't fall down in between the box and the wall. I left access to the power plugs and enough space to stow a backpack at the far rear corner.

 

[Hondarider]

My other concern, being an obsessive compulsive nutbag, is the potential for banging and clanging and rattling around...or...in a worst case scenario...a 4Runner rolling over on its roof and a 300lb storage box crushing my children. To that end, I'd have to devise a means of securing this bad boy inside the truck without drilling any holes or permanently altering the interior.

 

[Hondarider]

OK...that's probably more than enough titillation for such a mundane topic...so here's my finished (mostly) product. I took a few shortcuts at the end...mostly because I needed to get this monstrosity out of the garage tonight to make room for my car...and partly because I just wanted to see how it fit.

 

[Hondarider]

To secure the box to the 4Runner, I installed turnbuckles at all 4 corners. I'm certain that it will keep the box from bouncing under normal circumstances, but I can't be sure how it will handle in a rollover. I hope I never find out.


Here's where I got lazy at the end of the day. I opted not to upholster the sides or front of the box. I'm not proud of this decision...and I may go back and do it right later...but it was getting late and I was ready to quit for the day.

 

[Hondarider]

Turnbuckles at the front of the box take advantage of the hooks just behind the passenger seats. They seem secure.

 

[Hondarider]

No lock is impenetrable, and this simple barrel lock is not exactly robust, but it cinches the lid down tight when locked and it won't rattle like a hasp and padlock would. It also won't scratch up the plastic panel on the inside of the rear hatch.

 

[Hondarider]

Inside...I have 6.5 cubic feet of locked storage...I went with piano hinges for strength and added a spacer to support the center of the lid.

 

[Hondarider]

I considered carpeting the inside of the box, but I suspect that the tools and hard objects stored within will wear through the felt just from normal vibration. I do, however, have a roll of rubber for lining tool box drawers that I might try out.

 

[Hondarider]

So...that's about it...maybe I'll snap a couple more pics once its full...and then a ride review after a few bumpy roads.

 

[Hondarider]

Quick material list

-2 sheets of 3/4" plywood (I used just over 1 sheet) $60
-3 yards of black felt from WalMart $12
-1 bottle of wood glue $6
-1 can of 3M contact adhesive $9
-4 turnbuckles from Tractor Supply $12
-4 5/16" eye bolts $6
-2 piano hinges $12
-1 barrel lock $5

...and a pneumatic finish nailer with 15ga x 2" nails

Looks like I spent about $125. Now that I know that, I suppose I should go back and do a better upholstery job...that's not exactly pocket change. It adds up quick.

 

[calcrc]

I got myself and my friend/brother in law 2 Plano sportsman boxes each. Fits perfectly in my truck and he has the XL long cab so no problem for him.

I also got a killer deal at Walmart a couple of years ago I got 3 Coleman Duffle/Bug out bags for 15$ a piece and they are huge you can fit a lot of stuff in there.

Also got 2 Israeli gas masks with Nato filters. 200k litter water filter. 3 guns with a huge stack of ammo's in case the zombies come or the Russians come from up the North Pole!

But all that crap won't fit in the Runner alone. Need a trailer or something if you need to get out in the wild.

I got to fit 1/3 of the stuff in the truck but I will be prioritizing only for towing stranded on the road all the bags and boxes will be ready in the basement in case REAL $?&* happens.

 

[Hondarider]

Mostly I just needed a place to store my tennis racket, some Claritin, and a spare sweater vest.

 

[FrontRange4Runner]

Samurai sword.......You have finally figured out what the 4Runner has been missing all these years!

 

[Ron4RNevada]

I like it! I've been carrying my stuff around like this over the years:

Just lashed down

- and then covered with a sheet.

I'm thinking about doing something like yours with a couple changes:
Maybe only covering half the length of the load space and then using perhaps 3/8 plywood to save weight and some stiffeners inside to compensate.

I don't carry some of the stuff you do (like my samurai sword, air horn, Bill Clinton mask, etc.) so don't quite need as much space. I do carry some stuff like geology hammer, etc and sometimes a six gallon water jug.