Storage box write up
I use two 4' dog leashes to secure my dog in the back
Hinge locations
Hinge location
Hinge locations
Trimmed corners
Trimmed corners
Rear door closed
Rear seat covers
Design drawing
Staples
JK Rear Storage Write Up
Material List
3 each 1x4x8 for storage box
1 each 4x8 ½” sheet of plywood (not CDX)
2 each 2 ½” narrow hinges
4 each 2” strap hinges
2 each 3” x 3 ½” flush ring pulls (optional)
Monster wood glue
Small box 1 5/8” wood or drywall screws
Spray cans of contact cement
Carpet
½”x ¼” 18 gauge staples (to help secure carpet)
4 each small “L” brackets to secure storage box
Start by make the storage by using the 1x4’s screws and glue.
Per drill all screw holes to help prevent the wood from splitting.
Once you have completed the box you will to install an additional 1x4 on the front of the box to support the folding rear seat cover.
Make sure to glue all the joints for extra strength.
Cut the plywood for the storage box cover and secure it to the storage box using the narrow hinges.
Screw the hinges to the 1x4 that is closest to the inside of the box and then center the cover to the storage box and secure it to the hinges. This may require a second set of hands to help hold the cover.
Once you have completed securing the cover to the box you will need to test fit the assembly in the back of the jeep.
You will need to trim the rear corners of the box cover to slide the assembly close to the rear door.
Once you are satisfied with the location and fit of the storage box and cover you will to cut the plywood for the folding rear seat covers. Depending on the type of carpeting you are going to use you may need to add additional spacing between the 2 halves of the rear seat covers.
You will secure these to the storage box cover using 4 2” strap hinges, 2 on each of the folding covers. Make sure that the outside edges of the rear seat cover are square with outside edges and the rear of the box cover.
Once you have secured the folding seat covers you will need to test fit it in the rear of the jeep and trim the corners of the rear seat cover to fit properly in the rear of the jeep.
Once you are satisfied with the storage box you will need to disassemble it to install the carpet.
To carpet the storage box you will need to cut strips of carpeting about 9” wide and long enough to cover each section of the storage box.
You will need to use to contact cement to attach the carpeting to the storage box. Read the instruction to use the contact cement properly.
Once you ready to install the carpeting center each piece one at a time on the top of the 1x4’s so you can fold the strip of carpet in half and attach them to the side of the 1x4 with the ends of the carpet towards the bottom of the storage box.
Once you have all the pieces attached to the storage box us the ½” staples to attach the ends of the carpet strips to the bottom of the box to secure and clean up the corners and edges of the box.
Next you will install the carpet to the storage box cover. Make sure that the 4 2” strap hinges are still installed on the storage box cover, will be installing the carpet over these.
Cut you about 3” wider than the width and the length of the cover to help the secure the carpet with staples on the underside of the cover.
You will use contact cement to secure the carpet to the cover as before.
Next you will install carpet on each of the folding seat covers. The procedure for each is be same.
Cut your carpet long enough so that you can fold it half from the edge without the hinges and it will cover both side of the cover. Also make it about 3” wider than the width so you attached it to the sides of the covers.
Start by installing the carpet from the edge without hinges toward the edge with the hinges. You will need to attach the hinges from the storage box covers to the folding covers before you finish installing the carpeting on the folding cover.
Once you have the carpeting installed on the front and back of the folding cover you will use the stapler to secure the carpeting to the edges of the folding cover. Trim carpeting as needed.
Once you have completed one side verify that the space between the two covers is wide enough for the carpet that you are using.
The last thing to do once the storage box is complete is to remove the existing storage cover from the jeep and secure the storage box using the small “L” brackets.
