Expeditionary box build

[Rich84sr]

So after a while of camping in the back of my 4Runner on a old futon, I decided I wanted to go the expeditionary box route. Instead of going the custom fabricated route that costs $2500+, I decided to design and build my own.
1. I figured out what I would need and drew out a design.
2. Laid that design onto 1/2" MDF
3. I used Redwood for the framing ($ but very light)
4. With a 2" hole saw, I drilled out a grid to maintain structural integrity but lighten as much as possible. This shed about 12lbs.
5. Made drawers for bins #1 and #5. Used Pine for this.
6. Cut out the top board. Once again used MDF but because of the weight drilled holes and removed certain un-needed sections which removed around 30lbs off.

More to come!

 

[Rich84sr]

Additional Pics

Continuing on with the build.
Completing the build I used maple ply to cover all the holed out sections, but then ran out. Went back to Lowes and they had apparently run out too. So I settled for redwood ply for the bed section which is why it looks different.
Then I installed brackets for some shelving I'm going to install later. The center between the two drawers in this picture is also still uncapped. It is lined with foam all around and will contain an object that is about the same size and dimensions as an AR-15
Will get pics posted once all is complete.

 

[eddie333]

wow! this is impressive!

 

[Griz]

Wonderful work. Thanks for sharing your progress/build.

 

[Spenny]

Very nicely done and thought out!

Are you securing it down to tie down points or using the weight of your equipment? Also, really like the padded space in between!

 

[Cozmo2312]

You used to have a futon back there??

This I gotta see

 

[Taco04]

Great work love your special storage!

 

[RiDE]

Looks great! Definitely going to follow thi build.

 

[Rich84sr]

Thanks to everyone for all the positive feed back.

To answer a few questions:
As of now I haven't tied anything down yet. I used some rubberized grip padding underneath in combination with foam bumper roll around the front and sides incase of contact with the seat or side bolsters. All together the system weighs in somewhere around 140lbs, so it's not really going anywhere unless I roll it and in that case I don't think the tie downs would hold regardless.

Yes, a futon top fits in the back like a glove and is quite comfy. Although I did one up it for the new pad I put in and splurged by going to Wally World and buying a king size memory foam mattress topper and cutting it to size with several layers (pics to come).

 

[jkenn6]

wow! this is a sick custom box, I'm thinking about make one just for the trunk but I like your full box for long trips

 

[guitarsail]

What are the black rail looking things?

 

[Wandering1]

Subb'in. Really interested to see where this goes.

 

[Rich84sr]

What are the black rail looking things?

My original plan for the black rails I put in was to make a basket for the rear set and another for the forward set of rails. Before I committed I wanted to get some use out of it on a trip and see just how practical it was, and a good thing cause I have so much storage space now that it just became unnecessary. So instead I've decided to just put two of the rails down the far right side with a 36" stretch of back board with holes covered in bungie cords so I can just snap stuff in as I need it and it's out of the way when I don't.
I'll get some pics once it is redone.