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Boot box- ali, plywood or something else?
James - 28/6/12 at 05:19 PM

What a lot of posts today! Sorry!

Having finally got round to lowering my fuel tank I now have a bit more room for a proper boot box.

Any preferences on whether it's best to use ali or ply? I'll probably line it with some carpet from the donor or something.

As always, unemployment means this has to be done on a budget. I have access to a sheet of 8' x 4' ply at 4mm (ish) thick. Also have some leftover ali lying around somewhere!


Cheers!

James

blakep82 - 28/6/12 at 05:26 PM

fleece and fibreglass resin maybe? make a sort of wooden frame to the right size and shape, stretch the fleece fabric over and staple down, and paint resin on, leave to harden, and job done!
i'm going to try this myself soon, but i've seen it done on tv for car audio sub boxes and stuff

40inches - 28/6/12 at 05:28 PM

I use ply base and ally sides, I made a frame from 20mmx20mmx1mm ally angle.

James - 28/6/12 at 05:33 PM

PErhaps I meant boot, rather than boot box, if you see what I mean!

I know it's what a lot of people do, but any particular reason it has to be a 'drop in' box rather than just fixing a base and side panels to my chassis rails?
I can maximise the storage space with panels rather than a 'drop in' box I think.

Cheers,
James

40inches - 28/6/12 at 05:35 PM

quote:
Originally posted by James
PErhaps I meant boot, rather than boot box, if you see what I mean!

I know it's what a lot of people do, but any particular reason it has to be a 'drop in' box rather than just fixing a base and side panels to my chassis rails?
I can maximise the storage space with panels rather than a 'drop in' box I think.

Cheers,
James


That's wot I done init?

steve m - 28/6/12 at 06:36 PM

James

Mine is plywood/alui and has survied all this time that way,

The boot space is a bit limited though

Steve

pewe - 28/6/12 at 06:42 PM

James, I used external grade plywood (3mm thick IIRC) and formed thin ali sheet over it as a top cover with rubber beaded edges.
Into the cover I put a simple oblong hatch hinged at one end then Dzus fasteners at t'other supported by riveting the plates onto the top.
One thing to bear in mind is to make the aperture/hatch big enough to take a helmet - try two or three as they vary in size i.e. bike helmets are bulkier - ask me how I know!
Internally I did the perimeter with ali right angle screwed or rivetted to the chassis and then screwed tongue and groove bathroom (damp resistant) flooring laminate on top. That's not the lightest material but easy to cut and shape plus I had it in stock.
Mine will take two helmets+ or three bags of shopping!
HTH.
Pics if you need them or meet at the Pinewood on Sunday am for a look-see (weather permitting)?
Cheers, Pewe10