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DIY Rear Cargo Area
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Posted 4/27/2014 9:20 PM
Lbg500
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Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
DIY Rear Cargo Area

Here are a few pictures of the cargo area that I built today. I have been putting it off for too long...

I used:

4x8' sheet of 3/4" oak plywood for the base.
I had home depot cut the wood to the these sizes:

33"x59" wide
33"x11 1/4" (3x)
I had a 8' x 15" strip left over of plywood.

Once I got it home I made a few extra cuts. I cut one of the 33"x11 1/4" pieces about in half to still be able to access the CD changer. I had to notch out the area toward the back (not sure of these dimensions, 2.5" x 6"?, but I can measure them). I covered all pieces in gray indoor/outdoor carpet. Glued down and stapled in major areas. There is a little gap between the seat and the cargo area so that the seat can fold down. Otherwise it will get stuck. The large piece can be put in through the rear doors then maneuvered to the cargo area. I used a air nail gun to secure the vertical pieces. The oak plywood is very sturdy and is just about flush with the seats when folded down. The 59" dimension is about a perfect fit. You could go 58 and it may be a little easier to get in but I wanted a snug fit.

Feel free to contact me with any questions.




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#221586
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Author
Posted 4/28/2014 12:39 AM
So-Cal G
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Date registered: May 2011
Location: So-Cal
Vehicle(s): G500 2002
Posts: 93
50
Re: DIY Rear Cargo Area

that looks great man!
#221589 - in reply to #221586
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Author
Posted 4/28/2014 4:13 AM
Lbg500
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Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

Thanks! I wanted to use black carpeting but they only had the gray in the type I wanted. It matches the seat covers so I guess it works.
#221590 - in reply to #221586
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Author
Posted 4/29/2014 11:01 AM
Silver g500
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Date registered: Nov 2013
Location: Amelia Island, FL
Vehicle(s): 2003 G500, 1998 Volvo V70
Posts: 64
50
RE: DIY Rear Cargo Area

Lbg500, that looks good.

I am doing something similar to achieve a flat sleep platform. I also used ply, but cut it a little longer to achieve a slight overlap on the back of the seat, when they are down. I have another piece of ply which will butt up to this and lock (chest latch) in place.

I purchased German Imported Polypropylene Carpet from Miami Corp. This carpet is exact to the original carpet.
#221622 - in reply to #221586
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Posted 4/29/2014 11:48 AM
Silver g500
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Date registered: Nov 2013
Location: Amelia Island, FL
Vehicle(s): 2003 G500, 1998 Volvo V70
Posts: 64
50
RE: DIY Rear Cargo Area

Ref. attached.
#221623 - in reply to #221586
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Author
Posted 4/29/2014 12:03 PM
Silver g500
Regular




Date registered: Nov 2013
Location: Amelia Island, FL
Vehicle(s): 2003 G500, 1998 Volvo V70
Posts: 64
50
RE: DIY Rear Cargo Area

Sorry... again



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#221624 - in reply to #221586
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Posted 4/29/2014 1:12 PM
Lbg500
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Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

Looks good! What did you use for the center support for the platform? Do you know of any roll-up mattresses that fit in (fill) the space?
#221626 - in reply to #221586
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Posted 4/29/2014 1:36 PM
Silver g500
Regular




Date registered: Nov 2013
Location: Amelia Island, FL
Vehicle(s): 2003 G500, 1998 Volvo V70
Posts: 64
50
Re: DIY Rear Cargo Area

For the center support I used an item from ebay; eBay item number: 121119406696, foldable leg metal.
I usually fold them up, when not in use.

The mattress we use, which fits perfect and is very comfortable, is from Amazon; Kamp-Rite Double Self Inflating Pad.

Cheers.
#221628 - in reply to #221586
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Posted 5/4/2014 10:58 AM
colsG55
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Date registered: Aug 2013
Location: Dubai
Vehicle(s): G55 Classic 2000, TD5 110, 200 Series Land Cruiser
Posts: 211
100
Re: DIY Rear Cargo Area

Were you able to fit the main section of ply into place as a single section or as two sections as I tried similar with a single piece & was not able to rotate it into place.
#221678 - in reply to #221586
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Posted 5/4/2014 11:49 AM
Lbg500
Regular




Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

I was able to get it as one piece. I had to put it in through one of the backseat doors, with both back seats folded down, and both the driver seat and passenger seat moved as far forward as possible. Then I tilted it towards the drivers side down and passenger side up and slid it to the cargo area. It took a little wrangling but I got it in without any interior damage.
#221679 - in reply to #221586
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Posted 5/4/2014 10:07 PM
Silver g500
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Date registered: Nov 2013
Location: Amelia Island, FL
Vehicle(s): 2003 G500, 1998 Volvo V70
Posts: 64
50
Re: DIY Rear Cargo Area

Mine was 59" x 34 3/4".
One piece, two people make it easier.
#221687 - in reply to #221586
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Posted 5/5/2014 2:32 AM
colsG55
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Date registered: Aug 2013
Location: Dubai
Vehicle(s): G55 Classic 2000, TD5 110, 200 Series Land Cruiser
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Re: DIY Rear Cargo Area

OK thanks, I may have to try again knowing it can be done.

Mine in 59 x 32.5 so I will give it another go.
#221688 - in reply to #221586
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Posted 5/5/2014 11:21 AM
Lbg500
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Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

It is a bit difficult but I did it by myself, twice actually, first time to dry fit it before the carpet. Certainly worth it to not have any seams in the structure.
#221694 - in reply to #221586
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Posted 5/30/2014 1:00 PM
Lbg500
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Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

I would also recommend removing the 4 metal D-Rings (I ended up buying new ones) and reinstalling them in the corners on top of the new platform BEFORE the install. They were difficult to install once the platform is in.
#222153 - in reply to #221586
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Posted 5/30/2014 3:11 PM
Aircruiser
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Date registered: Aug 2011
Location: Atlanta GA
Vehicle(s): 2000 G500, 1986 300GD, 2017 Porsche Cayenne Hybrid
Posts: 364
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Re: DIY Rear Cargo Area

Nice work!

I'll post a few pictures of the shoe horn maneuver to get that man sized wood properly placed in the posterior. Hope it helps.

The material is green insulation board, it is cut to larger dimensions/max, than yours. It will eventually be a composite panel. Time and money.

Edited by Aircruiser 5/30/2014 4:01 PM




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Attachments g500unfinishedproject3.jpg (254KB - 21 downloads)
#222157 - in reply to #221586
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Posted 5/30/2014 3:33 PM
Aircruiser
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Date registered: Aug 2011
Location: Atlanta GA
Vehicle(s): 2000 G500, 1986 300GD, 2017 Porsche Cayenne Hybrid
Posts: 364
300
Re: DIY Rear Cargo Area

Lbg500 - 4/28/2014 4:13 AM

Thanks! I wanted to use black carpeting but they only had the gray in the type I wanted. It matches the seat covers so I guess it works.


I used that carpet on my gen. 1 for over two years. It holds up well but after a few summers it tends to drop glue dandruff when handled roughly. Nothing an occasional vacuum cleaning can't fix.

Small tip. To access the rear seat fold levers from above cut out a hand sized notch where the seats split. It is possible to access them from below, but it is an awkward maneuver. Mix in some ice or mud and it is a recipe for a cracked rib, ouch!

BTW. Love the RTT, thanks.

Edited by Aircruiser 5/30/2014 3:56 PM
#222158 - in reply to #221590
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Posted 5/30/2014 3:38 PM
Aircruiser
Extreme Veteran




Date registered: Aug 2011
Location: Atlanta GA
Vehicle(s): 2000 G500, 1986 300GD, 2017 Porsche Cayenne Hybrid
Posts: 364
300
Re: DIY Rear Cargo Area

Silver g500 - 4/29/2014 1:36 PM

For the center support I used an item from ebay; eBay item number: 121119406696, foldable leg metal.
I usually fold them up, when not in use.


Cheers.


Great product! I may end up stealing that idea in the future.
#222159 - in reply to #221628
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Posted 5/31/2014 1:07 PM
Lbg500
Regular




Date registered: Oct 2012
Location: FL
Vehicle(s): 2007 G500
Posts: 94
50
Re: DIY Rear Cargo Area

Yes, this Home Depot carpet seems pretty cheap. Nice work on the platform. That span (without center support) will come in handy. Why did you take out your other platform?

Glad the tent is working out! We should hit some trails in the next few weeks.

Edited by Lbg500 5/31/2014 1:10 PM
#222178 - in reply to #222158
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Posted 5/31/2014 2:34 PM
Aircruiser
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Date registered: Aug 2011
Location: Atlanta GA
Vehicle(s): 2000 G500, 1986 300GD, 2017 Porsche Cayenne Hybrid
Posts: 364
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Re: DIY Rear Cargo Area

Lbg500 - 5/31/2014 1:07 PM

Yes, this Home Depot carpet seems pretty cheap. Nice work on the platform. That span (without center support) will come in handy. Why did you take out your other platform?

Glad the tent is working out! We should hit some trails in the next few weeks.


I spent too much time surfing EP and decided I needed a fridge slide, drawers, dual battery, OBA, etc..., for my long trip out West. To build what I wanted it made the most sense to tap into the jump seat mounting points. Once I bit the drilling bullet, the shelf above seemed the best for general everyday use. For longer trips, 80% complete is more complex setup for long term travel and simplified living. I'll post some pictures later.

I picked up the Dengue Fever virus in the Yucatan in April and have been in the hospital or generally out of order since. Putting all of my projects on hold. Feeling better every day, though.

We will be in Mobile and Pensacola next weekend, it may work out.

Cheers,

Matt
#222181 - in reply to #222178
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Posted 6/8/2014 3:14 AM
colsG55
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Date registered: Aug 2013
Location: Dubai
Vehicle(s): G55 Classic 2000, TD5 110, 200 Series Land Cruiser
Posts: 211
100
Re: DIY Rear Cargo Area

After another attempt to get my board into place it went in today with a bit of stuffing around, it would have been nice to have a second person to help keep it off the interior.

I have also got my lower support in place but still need to secure the lot, carpet it & fit tie down points to the upper surface, will post some photos once complete.

#222281 - in reply to #221586
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