Boot box was made from 6mm plywood, cunningly designed to take advantage of all the available space in the rear of the car (allowing for suspension/diff travel).
The ply was PVAd and pinned, with the occasional piece of bracing wood. The shape was dictated in part by the need to go round the fuel filler and the light cluster.
It was made in two pieces to be screwed together once located in the boot space, as it wouldn't have fitted in if made all in one piece.
I treated the wood with 2 coats of Thompson's Water Seal plus one coat of fence paint.
The bottom compartment (about 10cm x 10cm x 70cm) is just right to hold a few tools. The compartment is lined with laminated flooring foam underlay, and the tools are held in place with some offcuts of foam. This section has a lift off lid.
In the lower part of the main compartment (above the diff) I stretched a piece of elastic cord cut off an old rucksack, to keep lightish things in place. I have also got a small ratchet socket set velcro'd to the base.
The final piece de resistance was to recess a Metro rear ashtray into the side - ideal for holding earplugs!
Based on rough calculations, it will hold getting on for double to volume of the old one.
Pics:
1. boot area with nothing in it (well, except for tank, diff, axle, etc.!)
2. new and old boot boxes
3. New box showing lower compartment
4. Lid on lower compartment
5. Stuff held in with elastic cord
6. Earplug storage
Not sure if I will really use it to transport vast loads of luggage (well, vaster than before), but anyway...
Lid/cover is another story
[Edited on 4/9/06 by Humbug]
Rescued attachment 2006-08 boot box.jpg
