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Unread 08-07-2012, 10:43 PM   #1
brplatz
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How To DIY Full Length TJ Trunk

TJ Full Trunk



Decided that before I head back down to school, which is in Las Cruces, NM. Just under an hour to Juarez and thought the jeep needed a few security updates. First was a DIY version of the classic ADE theft system. Next came a Tuffy Hood Lock. (Mainly cause my AC compressor was stolen last year).

Lastly came a secure/safe trunk. I rarely hold people in the back of the jeep, especially at college, so a full length trunk is the solution.

Design wise, I disliked the tonneau cover look; because then the space above the fender wells are useless, depending on the height of the trunk. My design goes to the full height of the tailgate but leaves the sides open for stuff aswell. Also the “front” side of the box is slanted at about 15 degrees to allow some space for my upper half door sliders. Ubolts were added as tie downs for coolers, luggage ect.

This design gives an approximate inner space of 33” Deep, 34” Wide, and 15” tall.

Materials:
One Sheet of MDF board
Roll of carpet 52” x 70”
2" Wood Screws
4 5/16” bolts are needed, about 1.5” long
Wood glue
Couple of ripped 2x4s which end up being 1.5" x 1.5"
Table saw and Chop saw and Jig saw
Exacto Blades
Total Cost was about $70 from Lowes.
Some solidworks drawings. These are extremely close, but some tweaking may be needed.







Started taking some basic measurements, and cut my side panels and braces
All of these are pilot drilled and wood glued.


2 Panels Completed


Sides meet front panel



Top on



Test fit for notches and mounting holes, I just slid it as far as it would come, then took measurements with a tape measure and marked for clearance. Added ¼” for carpet thickness.
For the mounting holes I used the 2 5/16”-18 holes. And match drilled them after I cut the notches and it was in its final position. 4 5/16” bolts are needed, about 1.5” long


Notches cut and sanded.


Picture showing the angle, about 15 degrees.


Epoxy for glue and seal of the board. Had this from an old project, sets in 6 hours or something. Cost of these 2 new are about $100, so not cheap. I used this more for sealing the MDF and less for glue. Probably could substitute Polyurethane.


My dad applying epoxy to the outside after the carpet had been test fit and cut to shape.


Applying scotchgard to the carpet, who knows if it does anything but can’t hurt.


Done



Brown is a rubber seal for doors and such. Also will take more pictures in the sunlight.
End result: To be honest I made it a bit high, so the tailgate seal is a bit high but still good and makes the rear window “bar thing” a bit tough to get in.

The drawings are slightly modified to include changes that were needed.

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Unread 08-08-2012, 07:23 AM   #2
wage
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BRplatz

Awesome write up. Thank you for sharing. I did something similar for my LJ, except mine has a lockable pull out drawer and uses the tabs in the bottom of the rear floor to anchor it down. On the top side I installed a set of removable gun racks as I hunt a lot. And I did not make drawings cause if I did no one could read them. Lets just say even my stick figures look menatly challenged.
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Unread 08-08-2012, 07:33 AM   #3
KEH1997
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Well done... looks very clean. I would consider something like this if I didn't use my backseat so much.
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Unread 08-08-2012, 09:24 AM   #4
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Very cool! I think an enclosed trunk is one of the best mods you can make if you don't carry people/dogs/goblins/whatevers that often. Taking the rear seat out of mine was the smartest thing that I did; a TJ is essentially a two-person rig, and giving yourself extra/secure cargo capacity in the rear is a great way to go!

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Unread 08-08-2012, 10:56 AM   #5
brplatz
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Thanks guys! And yes I think it's gonna be one of my best mods to date. Besides the security I always hated stuff just bouncing around in the back.
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Unread 08-08-2012, 12:25 PM   #6
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Quote:
Originally Posted by brplatz View Post
Thanks guys! And yes I think it's gonna be one of my best mods to date. Besides the security I always hated stuff just bouncing around in the back.
You might want to consider some logistic track mounts, then. They're low-profile and very strong; I'm running 24" sections of it on top of my hard deck cover/tire carrier. Here's a link, if you're interested.
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Unread 08-08-2012, 12:30 PM   #7
brplatz
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Damn I really like those. That track system is sweet
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Unread 08-08-2012, 12:34 PM   #8
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Quote:
Originally Posted by brplatz View Post
Damn I really like those. That track system is sweet
I've got a half-dozen of the round pucks to go in the bed and - as stated - 24" sections going on the deck cover. The removable nature of the tie-down rings is what makes it so nice; fewer snags and protrusions when they're not needed.
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Unread 08-08-2012, 01:48 PM   #9
jeepjerryp7m8
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Very nice. Might build something like that myself. Might hinge and lock the lid though, in case I have to carry something that is a little taller. Nice build.
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Unread 08-08-2012, 02:08 PM   #10
brplatz
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Quote:
Originally Posted by jeepjerryp7m8
Very nice. Might build something like that myself. Might hinge and lock the lid though, in case I have to carry something that is a little taller. Nice build.
Jerry
Good call, and with this design a hinge would be cake. Not sure on the lock, but I'm sure it wouldn't be terrible
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Unread 08-08-2012, 02:27 PM   #11
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Quote:
Originally Posted by brplatz View Post
Good call, and with this design a hinge would be cake. Not sure on the lock, but I'm sure it wouldn't be terrible
A simple drill-through drawer lock would work.
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Unread 08-08-2012, 03:25 PM   #12
brplatz
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Haha I must be over thinking it all.
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Unread 08-08-2012, 04:14 PM   #13
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How much does it weigh?
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Unread 08-08-2012, 04:20 PM   #14
brplatz
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Quote:
Originally Posted by Jeepsr4me
How much does it weigh?
Maybe 65 or so pounds. It isn't light.

The 4x8 MDF is 65lbs by itself. We use most of it plus carpet, epoxy, screws and the supports.
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Unread 08-08-2012, 06:52 PM   #15
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Quote:
Originally Posted by brplatz View Post
Maybe 65 or so pounds. It isn't light.

The 4x8 MDF is 65lbs by itself. We use most of it plus carpet, epoxy, screws and the supports.
Its nice looking but thats a heavy piggy !

I made mine out of steel to save weight . I ended up at about 15 lbs , but mine isnt as big as yours .
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