I figured it was about time that somebody made a thread about this popular mod for reference and to be added to the FAQ some day.
There are many different threads but they were never able to answer all of my questions regarding how the cans were mounted and how those brackets were made when I put my can in. So, I'll try to be as specific as possible in this thread and even make a list of links to the write-ups others have done before me.
(In a TJ but same basic concept)
(Not a write up, but good pics for ideas on both pages)
Here's how I did mine.
-20mm ammo can ($25)
-Flat olive drab paint ($5)
-6 bolts/washers/lock nuts (Free)
-Scrap angle iron (Free)
To save me some trouble I welded the back latch to the can on the top and sides of the latch. That way I woulden't need to put a lock on both sides. You'll also want to take a grinder to the back "lip" of the can so that the lid will open more when the back latch is welded in place. Try to fully open the lid on your can with one latch still on and you'll see why this is neccessary.
I welded up the frame for the rear of the can to sit on. Because the seats are offset in the YJ the can isen't centered in the direct center of the transmission hump, but rather a couple inches to the passenger side of the Jeep. That means that the bracket would also have to have two different sized legs because of the way the passenger floorboard is shaped (has that mini hump in the center).
I used some 1" angle iron. One peice across the back to bolt the can to, two legs, and I cut some square pieces to be used to bolt to the tub of the Jeep. I then painted it olive drab to match the can.
I drilled holes in the center of the bottoms of the bracket's legs. Then I marked the holes where I wanted to drill the holes in the tub and drilled away.
The more you drill holes and cut away at the body, the easier it gets!
I then bolted the bracket to the body using my bolts, washers, and lock nuts like so. (It helps if you have a friend to help by holding a wrench on top or going under, I didn't at the time so I had to rig it all up
I then drilled two holes to connect the can to the frame. I just put one mark in each corner and drilled away. Then I added bolts, washers, and lock nuts.
Outside (Note how the can fits right in the angle iron's angle.)
The can is now secured in the rear but not the front. Time to drill some more holes! I put two more holes in the front and spaced the out some for stability. It moved a little side to side with just one but was rock solid with two, so I stopped with two. Held down with bolts, washers, and lock nuts.
Here's a view of the underside of the Jeep. It would be hard to steal this thing by unbolting it due to the locations of the exposed bolts. Trying to pry it off of the body would also be dificult.
Here's how it sits now. (Minus lock)
I had always wanted a console ever since I got the Jeep in May 2008. Having all of my stuff blowing around when the roof and doors off sucked, having a small plastic glovebox as my only source of lockable storage was even worse.
So to me this project was a real success. I can store TONS of junk in that ammo can.
The can is fairly safe since the bolts are hard to get to, the back latch is welded to the can, and there is lock on the front. There are ways to get around it of course, nothing is completely secure, but if it will help keep honest people honest and secure my stuff that's all I wanted. Plus having an arm rest now on long trips is amazing!
If anybody has any specific questions or other threads they'd like me to add just say so