Made a rear cargo storage shelf for my 4XE (DIY)

[Andy@AAV]

I had a plywood and 2x8 temporary solution for almost 3 years so I finally got around to making the real version that had been living in my head. I used 3D printed parts along with some 1x1 aluminum tube and some old airline track I had in the garage. First step was getting the base made, I printed some blocks out that leveled and aligned a piece of square tube where the factory tie-down rings were installed.

Next I made the vertical supports and printed some T-brackets that are bolted through with 8-32 bolts and JB welded in place. The top square tube piece has 1/4-20 threaded inserts that match the hole pattern in the airline track.

Cross supports are 1/2 x 1 aluminum angle that are drilled and countersunk for 8-32 flat heads that are threaded into hammered inserts on the plywood shelf material.

The center support is free floating on the bottom and bolted in place through the airline track.

Last step (almost) was to install everything and find out my 1/4-20 flat heads weren't quite long enough to fully thread into the inserts on the square tube.

Once I got longer bolts everything was test fitted and then I glued/tacked carpet on the plywood so it looks less ghetto...

3 months in and everything is holding up fine after a few trips and 5k miles. I made some 3D printed end caps for the aluminum tubes so it wasn't so sharp. Black parts are printed from carbon-fiber nylon and the blue parts are ASA.

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[Sandevino]

Looks solid! I'm working on something similar with the ability to raise or lower the platform to accommodate bulkier items underneath.

 

[RicRecon]

Looks solid! I'm working on something similar with the ability to raise or lower the platform to accommodate bulkier items underneath.

That would be cool to see

 

[etoften]

Love it! I have been trying to figure out storage in on my soft top. Trays on the market are too tall. The sit above the pockets for the top when open. The top gas to sit on the tray. Worried about wear, heat from the sun shining on the metal, and loss of visibility due to the top resting higher. Current drawer systems are low enough but you actually net less storage due to the hardware. Iwas thinking of doing exactly this leaving the top of the shelf even worth the bottom of the soft top pockets. I couldn't figure out the frame work under it. Definitely copying that aspect of your build. Thanks!

Curious why you didn't bring it up all the way to the pockets though?

 

[Andy@AAV]

It sits even with the rear seats when they’re folded so I can pull the fridge out and have a flat floor for bigger stuff.

 

[etoften]

It sits even with the rear seats when they’re folded so I can pull the fridge out and have a flat floor for bigger stuff.

That makes perfect sense. I was thinking of maximizing room under it and still allowing the softtop to go fully down. My version would serve more as a true trunk. Awesome project

 

[Wkaz]

Wish I had/knew how to 3d print. Looks like it will hold up well. I custom fabbed some brackets for a Molle Platform Solutions rear tray. I haven't been able to figure out gas strut mounting that stays in place over rough roads so it's thumbscrews for 3 years now.

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