DIY Rear Cargo Shelf

[ninetubes]

I sketched up a rear cargo shelf and had it laser cut, bent and powder coated.

Looks great, so thought I'd share the cad file for anyone that is so inclined. Sorry about the .zip, it wouldn't let me upload a .dwg
Most sheet metal shops could make it happen for you by sending them the cad file.

I made it from 2.0mm alum. I'h very happy, but some may prefer to go to 2.5 or 3.0mm.

You’ll also need:
Ten M6x10 nut/bolt/washers to bolt the parts together. You can also use M6 rivnuts if you prefer.
Four M8x25 bolts to bolt it to the car
Four 10mm thick washers, I used a hole saw to cut them from some 10mm plastic bread board. The outside diameter needs to be 40-50mm and the hole in the middle 9-10mm.

To fit, simply pop the four trims out of the roof and attach to those bolt holes with the big washers in there so the brackets don’t squash the roof lining – done.



Cheers, Dan

 

[Clark Kent]

Looks great. Thanks for sharing Dan. Kaon better watch out!
Would you please post a pic looking towards the shelf from an open rear passenger door. I'm interested in how far forward the shelf extends towards the rear seat and the height above the headrests.

 

[ninetubes]

Looks great. Thanks for sharing Dan. Kaon better watch out!
Would you please post a pic looking towards the shelf from an open rear passenger door. I'm interested in how far forward the shelf extends towards the rear seat and the height above the headrests.

It's a pretty blatant knock-off of theirs and I wouldn't normally do that to a local manufacturer. BUT, when i first asked them about doing one I got a pretty flat "no", so i got cracking with my own.
I'm not concerned that this will take business away from them, as DIY isn't for everyone and making one at a time puts the cost at about what i imagine theirs will be anyway.

But for those as impatient as me (or overseas), this might be an option so thought i'd share it

 

[Tazzieman]

Kaon have told me their version is not likely to be available until the latter 1/2 of 2024.
Which is a pity.

 

[TheDocAUS]

Great design, thanks.

I intend to install one in my 2 seater. Do you use exiting holes for the bolts or did yu drill them?

 

[ninetubes]

Great design, thanks.

I intend to install one in my 2 seater. Do you use exiting holes for the bolts or did yu drill them?

There are four M8 threaded bolt holes in the top of the cargo area. Just pop off the four square trim covers to find them.

 

[Krabby]

That is awesome - thanks for sharing. I'll have to check around for fab shops in this area.

 

[Pat-Ard]

There are four M8 threaded bolt holes in the top of the cargo area. Just pop off the four square trim covers to find them.

@ninetubes Thanks for sharing the file!!! That's really great!

How did you pop off the covers?

 

[ninetubes]

@ninetubes Thanks for sharing the file!!! That's really great!

How did you pop off the covers?

Just pop it off with a trim tool, or might be able to pull it off by hand if you can get your fingers behind it.
These are cheap and handy:

 

[ECrider]

I sketched up a rear cargo shelf and had it laser cut, bent and powder coated.

Looks great, so thought I'd share the cad file for anyone that is so inclined. Sorry about the .zip, it wouldn't let me upload a .dwg
Most sheet metal shops could make it happen for you by sending them the cad file.

I made it from 2.0mm alum. I'h very happy, but some may prefer to go to 2.5 or 3.0mm.

You’ll also need:
Ten M6x10 nut/bolt/washers to bolt the parts together. You can also use M6 rivnuts if you prefer.
Four M8x25 bolts to bolt it to the car
Four 10mm thick washers, I used a hole saw to cut them from some 10mm plastic bread board. The outside diameter needs to be 40-50mm and the hole in the middle 9-10mm.

To fit, simply pop the four trims out of the roof and attach to those bolt holes with the big washers in there so the brackets don’t squash the roof lining – done.



Cheers, Dan

Epic fabrication and thanks for sharing all the relevant details.

I'd really like one of those but need the full height of my boot most of the time.

 

[Tazzieman]

I'm wanting to pop the roof plugs off over the front seats.
I've squeezed bloody hard with the right tool but all I'm doing is crushing the foam.
WTH?

 

[Logsplitter]

I'm wanting to pop the roof plugs off over the front seats.
I've squeezed bloody hard with the right tool but all I'm doing is crushing the foam.
WTH?
View attachment 7839257

I’ve got one of those as part of a set and found it hard to use. Now I just use the levers

 

[Clark Kent]

I'm wanting to pop the roof plugs off over the front seats.
I've squeezed bloody hard with the right tool but all I'm doing is crushing the foam.
WTH?
View attachment 7839257

You borrow many tools from work @Tazzieman ?

 

[ninetubes]

I'm wanting to pop the roof plugs off over the front seats.
I've squeezed bloody hard with the right tool but all I'm doing is crushing the foam.
WTH?
View attachment 7839257

I tried getting the rear roof plugs out but stopped when I couldn’t get it out. Ended up using a cable snake to run wires through the headlining. Was shocked when it worked first go!

 

[parb]

Any recommendation for an machine shop that takes online orders?

 

[Jetjockey]

I sketched up a rear cargo shelf and had it laser cut, bent and powder coated.

Looks great, so thought I'd share the cad file for anyone that is so inclined. Sorry about the .zip, it wouldn't let me upload a .dwg
Most sheet metal shops could make it happen for you by sending them the cad file.

I made it from 2.0mm alum. I'h very happy, but some may prefer to go to 2.5 or 3.0mm.

You’ll also need:
Ten M6x10 nut/bolt/washers to bolt the parts together. You can also use M6 rivnuts if you prefer.
Four M8x25 bolts to bolt it to the car
Four 10mm thick washers, I used a hole saw to cut them from some 10mm plastic bread board. The outside diameter needs to be 40-50mm and the hole in the middle 9-10mm.

To fit, simply pop the four trims out of the roof and attach to those bolt holes with the big washers in there so the brackets don’t squash the roof lining – done.



Cheers, Dan

Great work, Dan!

Where did you get, or better what brand is the compressor connector/switch panel?
Couldn't find something like it online.

Thanks
Oli

 

[RobHallieSage]

I sketched up a rear cargo shelf and had it laser cut, bent and powder coated.

Looks great, so thought I'd share the cad file for anyone that is so inclined. Sorry about the .zip, it wouldn't let me upload a .dwg
Most sheet metal shops could make it happen for you by sending them the cad file.

I made it from 2.0mm alum. I'h very happy, but some may prefer to go to 2.5 or 3.0mm.

You’ll also need:
Ten M6x10 nut/bolt/washers to bolt the parts together. You can also use M6 rivnuts if you prefer.
Four M8x25 bolts to bolt it to the car
Four 10mm thick washers, I used a hole saw to cut them from some 10mm plastic bread board. The outside diameter needs to be 40-50mm and the hole in the middle 9-10mm.

To fit, simply pop the four trims out of the roof and attach to those bolt holes with the big washers in there so the brackets don’t squash the roof lining – done.



Cheers, Dan

very utilitarian lookin' - nice rig!!!

 

[ninetubes]

Great work, Dan!

Where did you get, or better what brand is the compressor connector/switch panel?
Couldn't find something like it online.

Thanks
Oli

Hey Oli,
Both ARB brand, which is quite popular down here.
More details in my build thread here:
https://www.theineosforum.com/threa...ld-western-australia.12414087/post-1333244369
https://www.theineosforum.com/threa...ld-western-australia.12414087/post-1333244369

 

[ninetubes]

Any recommendation for a machine shop that takes online orders?

Googled this for you

Online Laser Cutting in San Francisco, CA | SendCutSend

Online laser cutting in San Francisco, CA specializing in aluminum, steel, brass, plastics, titanium, and more. Fast turnaround + free shipping!

sendcutsend.com

 

[ninetubes]

I just did a run of ten of these for local owners. Used 3.0mm for the tray which is very sturdy, definitely recommend it!