MOD: Rear cargo revamp.

[MrSmithsTB]

I had a fairly sizable subwoofer enclosure until just a few days ago. But last weekend, I mounted my 33" spare. As most of you know, that will not fit under the vehicle anymore. I don't have a roof basket either, so I had to put it in the cargo area. That really made me realize just how much space was being wasted by the monstrous enclosure.
During original construction:


I started thinking and came up with my ultimate goal. Keep as much of the sound quality as possible and increase storage, while making room for the spare to be carried inside. I know the obvious place to mount the larger spare is up top, but I find that to be impractical for everyday driving. One more item that can fly off on the highway and it is an unnecessary nuisance to have to pull it from way up there if you need to use it. Also, since most of my driving is city, I don't the the hitch mounted carrier because I do not want to be longer than I have to. After a few design tweaks, this is where I have settled. I still have some finish work, and will be designing a modular tool/parts box for trips, but overall I am happy with the results. Box it sealed now, but almost as loud. I have regained easy access to the in floor storage, and the tire is secure and out of the way. Best part is, aside from a couple of hinges and bolts I need to pick up this afternoon, everything used was already in my possession





I will provide better photos once it is all buttoned up and cleaned.

[foosh]

Its simple, but i like it! Good work man... its giving me some interesting ideas for when i finally do mine, Although i will be carrying the spare up top because it takes up sooooo much interior room.

[MrSmithsTB]

I am definitely putting it up top for trips and such, but i needed a safe place for everyday use(gotta watch that gas mileage too!). The "modular" tool box is going to be sized to fit in the spot for the spare and all the rest is opened up for everything else under the sun.

[foosh]

Yes the mpg!!! I was planning on only carrying it on trips, when i'm local i can always have someone drop it off to me. But for trips where cargo size is important its going up top... And i'm working on a new detaching method for my rack so it stays off unless i actually need it.

But i really like your idea, i'm thinking about doing that for both sides, and building it all the way flush to to window, so it has that little bit extra of usible space... we'll see, its being put on hold for me with the Body lift and all coming soon.

[Trail X]

Bot, do you recall what the Torx size was for the stock bolt in there? I've stripped it once already thinking I could cheat with a T-40.

I didn't have anything bigger.

[MrSmithsTB]

I'm going to have to check my tool box. I just grabbed a loose one and it happened to fit. If I am not mistaken, it is a T-45. Same size as the seat belt.

Edit: Just checked. The bit size is T-50.

[Trail X]

I assume they're lock-tite'd... mine loosened, but still doesn't want to budge much... I'm just going to have to go get a proper torx kit.

[MrSmithsTB]

They didn't look like it. But they do go straight through the floor and are exposed to weather, so they could be binding for that reason.

[Trail X]

I found a T45 and went to down on the bolt, still with very little luck. It came out an extra turn or so, and now is almost cemented in place. My impact wrench will just sit on it without turning the bolt. Little by little I'm eating away at the T45 engagement now. I need a breaker bar.

[The Roadie]

I need a breaker bar.

So, you're admitting in this forum that you don't own at least three breaker bars? Power tools aren't ALWAYS the answer, although I've always said if a job's worth doing, there's a power tool to help you do it. (Or was that Tim Allen who said it?)

[Trail X]

Hehe... it's at home. I'm at work.

Although I do admit I didn't have a T45 at home.

[Trail X]

Crap... I found a breaker bar at work... and completely stripped the Torx socket.

[arnold schwarzenegger voice] It's because I'm so muscular. [/arnold schwarzenegger voice]

I guess it's time to break out the stripped screw remover...

[Gordinho80]

Damn, Superman... should have taken it easy on that bolt... a little lube goes a long way.

[foosh]

You could just shoot it out !!! But ad some lube first, you can never use enough lube, well actually...

[MrSmithsTB]

See what happens when you use the wrong size bit? I know you are south of the Mason-Dixon, but I was trying to give you more credit then your geographic allowance

[Philberto]

Harbor Freight Ratchet + Factory Bottle Jack > Any stinking breaker bar

[foosh]

Ummm Philberto, hows this useful?

[Trail X]

I guess it's time to break out the stripped screw remover...

So I threw tons of liquid wrench on the sucker yesterday...

Today I used my stripped screw remover on the bolt... the bolt broke my screw extractor in half... gotta see if that's under warranty... substandard chineese crap.

Anyways, I decided to grind down flats on either side of the bolt head. Grinding went fine, got a wrench on it. Turned it about 3 more turns, no problem. Snap. The //// nut broke the spot welds on it!

So I have a seized nut on a bolt that's stuck through the body, and is about 5 turns loosened. Had to take the only option left... cut the sucker off.

Now I'm not even on square one... more like square zero.

Moral of the story?... check the bolt... if it's rusted, leave it alone!

[MrSmithsTB]

Ouch! I figured my 02 living two miles from the Ocean would give way more problems in that respect. FYI, I used stainless hex heads to replace the originals.

[Philberto]

Ummm Philberto, hows this useful?

Simple... place the harbor freight ratchet with correctly-sized bit on the fastener, and then utilize the bottle jack (or a scissor jack from some other car) between a sturdy surface and the handle of the ratchet to apply massive amounts of torque to the fastener. It was more of a humorous suggestion as an alternative to a breaker bar than anything.