My in-vehicle storage system

[mvcoller]

When I sold my Terrano and acquired my TD30 Di 2008 Patrol GL in 2016, I had to build an in-vehicle storage system fairly quickly. I used my vehicle for my 4x4 guiding and Off-road Touring business. I had to do this before the next tour came along.

The Terrano had much less space in the rear, so in that I used ammo boxes as storage and I just transferred the idea to the Patrol.

I built the rack in the back of the Patrol mainly from 25 x 25 x 1.6mm angle iron, welded together. I built it bit by bit, fitting each section into the vehicle, measuring, taking it out and building the next bit. Once completed, I fitted the steel frame into the Patrol and then fitted the 10mm plywood surfaces. I had to do it afterwards, as I could not fit it if the wood and steel was bolted together in one piece; the wood fitted the vehicle exatly from side to side. I cut a removeable aperture on the left of this shelf to fit the battery through, into the box above the wheel arch, where the battery lives in what was unused and wasted space.

The fridge slide I built in the mid 1990s and fitted it into my then Racing Car Tow Vehicle (it was actually my company car from FNB (who I was working for), a 2.4 Venture GLE with a LS Diff. When I got rid of that vehicle, the slide went into my Sani, then into my Terrano and eventually into the Patrol. That was a solid piece of my kit and has never given problems, so that was the first starting block in the Patrol's storage system. I then fitted 4 ammo boxes, two high lid models lengthwise at the bottom and two flat lid versions above that.

That left quite a lot of storage space at the top section of the rear packing area. The flat surface above that left enough space for the top 10mm plywood and sufficient space above the fridge freezer to ensure good air movement. Because of the tight space left for the two slide out racks for the ammo boxes, I could not fit the strong drawer slides (15mm wide per side) as was used for the fridge. there was only space to use the narrower 10mm weaker drawer slides.

For the top slide (the two top ammo boxes is for our clothes), that was not a problem, but for the bottom high lid boxes, those weaker narrower slides would not be strong enough.

The two lower boxes were used for;
No 1 for kitchen utensils, plates, pots, cutlery, bowls, etc and for
No 2 for all the non-perishable food and tins of food (could stack 2 x 410gr food tins on each other)
That made for a very heavy drawer, and corrugated roads would destroy the light sliders in no time, so I welded one slider on top of another, hoping that they would be strong enough to last. Thankfully it seems to be, it has lasted from 2016 and is still going strong. Under this I have working surface that slides out of the bottom slider, below the two bottom boxes. This can slide in and out from below this lower shelf, whether the bottom self is itself slid out or still in place. This means we need not take anything off the working surface, when sliding the lower ammo box out.

There was enough space in front of the in-vehicle storage system to fit a 50lt Pioneer Plastics water tank (https://www.pioneerplastics.co.za/colle ... water-tank) behind the rear seats. Under the water tank I fitted the disassembled high lift jack and a small (brick sized) safe, bolted to the floor with large washers under the floor, 10mm high tensile bolts and nylock nuts)

At a later stage, because I was not using the rear seats, I removed those, made space for two more ammo boxes (1 for clothing, shampoos, creams etc., for the Baas!!, a second one for my beers), a plywood drinks cabinet, storage self for the folding chairs, camping lights and two plastic milk crates for cold drinks, fruit and vegetables.

I fitted a safety barrier in front of the top packing surface and this gave me the perfect location for the Victron equipment and a secure space the cable tie the electric wiring, safe and secure, out of harm's way. I can unclip the barrel bolts on the top and hinge the "Clear View Fence" safety barrier down, forward, to access the rear of this barrier (where all the wires and the Victron Smart Shunt is) and also to access the front of the top shelf.

I fitted a male kettle plug to the front grill of the Patrol, it connects to a 220v system inside the vehicle. This feeds the 5a CTEK charger to keep the Patrol's starting battery going (I sometimes do not start the Patrol 3 or 4 months) and the run the fridge freezer and also to keep a float and maintenance charge on the LiFePo4 auxiliary battery. All I have to to is plug the kettle cord in the carport into the Patrol....

[Witbobbejaan]

Thanks for detailing your build Malcolm. The drawers that pull out towards the rear seat area is something I haven't seen before...clever.

It looks like the safety barrier is bolted into the plastic fittings on the side...is that so? I've always wondered how well anchored those things are in the case of a violent brake situation...

[mvcoller]

Thanks for detailing your build Malcolm. The drawers that pull out towards the rear seat area is something I haven't seen before...clever.
No, those are not drawers, those are fixed "shelves" where I store chairs etc in. I actually have straps over them to hold the chairs in place. In the picture, the straps are not actually fastened over the chairs. It also has a narrower shelf below that one, with nothing in there at this stage, and may never have, other than perhaps a box or three of biscuits.

It looks like the safety barrier is bolted into the plastic fittings on the side...is that so? I've always wondered how well anchored those things are in the case of a violent brake situation...
The safety barrier has a frame and this frame (25 mm x 25mm x 1.6mm angle iron) is very securely attached (bolted) to the main steel frame of the whole system. The opening section is attached to this frame via a hinge near the bottom outer sides of this section. Those two 6mm bolts, one on each side at the top, is just to add stability for the frame not to rattle. Inside the plastic sides, I fitted a 75mm x 75mm x 1mm thick steel plate. I smeared it with a dollop of "No More Nails", battled my ali off to hold it in place (with two fingers) and bolting it tightly in place with those 6mm stainless bolts and nuts (with the other hand). It was quite stable before fitting that bolt, the bolt just make sure that it does not even move 0.10mm!!