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Old 05-20-2013, 12:44 PM   #1
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Rear tool box/hi lift mount/tire mount

While on the trail I have an assortment of tools, fluids, recovery gear, and a 33" tire in the back and on the floor of my 88 YJ. It would roll around fluids would open and spill, tools would bounce around, so I decided I needed some sort of tuff box for the rear and after looking at prices and the quality of the box I decided to make my own.

I picked up a 90 amp welder from Harbor Freight and decided to learn to weld, teach a man to fish I guess, so here is what I've "created" so far, please remember this is my first time welding.

Welder and work tables I made out of the neighbors cabinets he left outside with a free sign
[IMG][/IMG]

Using Magnetic 90 degree angle makers I made my cuts and began to run a few beads
[IMG][/IMG]

Lid setup
[IMG][/IMG]

This my best weld so far
[IMG][/IMG]

Started with .016 gauge square tubing for the framing of the main box and the lid
[IMG][/IMG]

The frame for the main box and the lid welded and prepping the sheet
[IMG][/IMG]

After cleaning and cutting the .016 sheet metal I mocked it up
[IMG][/IMG]

All sides welded up except the front, decided to try my hand at a little more technical metal working techniques, rolling or rounding the metal
[IMG][/IMG]

To roll the metal I had to make a new front plate with slight over hang/lip at roughly 3/4 inch, and small notches cut out to help roll the metal, come out to look like this
[IMG][/IMG]

sides with notches cut out
[IMG][/IMG]

After some heating from the BernzOmatiC and my trusty hammers I rolled the bottom and to the sides to give me a nice looking finished front plate
[IMG][/IMG]

had to give this corner a heavier beating
[IMG][/IMG]

Main portion of the box complete time to start the lid
[IMG][/IMG]

This is where I'm at so far will be putting in more garage time this weekend.

Should I run the Hi lift on the hood and reinforce the lid to support my spare tire? or just build a swing triangle tire mount for the bumper?

suggestions would be great

Thanks!

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Old 05-30-2013, 09:02 PM   #2
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More Work

Getting more work done on the box!

Took some more pics of what it may look like...

Put main security bolt hole in with a rubber grommet and some RTV for sealing
[IMG][/IMG]

From the bottom...


Welded rolled sides in the front (welds are getting better!)...


Top tacked welded...


Just mocked this up as an idea... What do you think?


Any ideas that you can think of or comments would be great! will be adding more soon!

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Old 05-31-2013, 02:12 PM   #3
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Looks pretty stout, wont have too many tools rolling around in their.
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Old 06-01-2013, 01:36 AM   #4
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when you finish getting it boxed up a good way to keep your tools in place is to build smaller divided sections inside and line them with cubed foam. pull out the foam to match the tool outline and push the tools in. yeah it takes up a little extra space but your tools will always be organised, never rattle, and never get hidden under other tools. the same can be done for your fluids. i plan on doing something similar in my jk but rather than bolt it down im going to have it lock onto the factory rear seat mounts so i dont have to drill into the body.
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Old 06-01-2013, 11:39 AM   #5
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That's a good idea, I'll have to pick up some foam and give it a try. Thanks for the input.
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Old 06-01-2013, 02:11 PM   #6
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not a problem
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Old 06-14-2013, 09:08 AM   #7
Guesses a lot ;)

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I like the tire mount on top of the box. I plan on having two spares eventually and your work has inspired me. I might have missed it but are you gonna put shocks on your lid of your box? Like a canopy or jeep hard top?
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Old 06-14-2013, 09:33 PM   #8
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DANG!!!! Impressive project!!!

.....now maybe ~I'll~ have to buy a welder....


Thanks for the fine write up!
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Old 06-15-2013, 01:17 PM   #9
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I'll be doing more work and hopefully finishing this project within the next 2 weeks just got married last weekend so that and the honeymoon has taken up a lot of my build time. I will be posting more pics too!

OregonPlinker: I was thinking about it putting a small shock, but not sure yet. As far as your second spare I'm going to be doing a build for an A frame rear tire mount that sits on the diagonal portion of the roll bar and doing write up on it. It will be detachable with some sort of shackle cuff too so if you wanted to put the rear seat or your hard top on you can. but keep a look out for that one, may not be for awhile. But glad I could give some inspiration and hope you'll do a write up too!

JeeperJake: I picked up my welder form harbor freight for $100 bucks and I must say it was well worth the money I have never welded before and it's a lot easier than you think, just watch a few vids on youtube to get the jist of then get some scrap metal and practice. you'll get it down pretty quick. It's a lot of fun too and you project list will be endless of things you can make. Just don't use that welder on any heavy duty parts like suspension, more of a fab welder than anything. Remember, all things can be challenging but the reward is worth it. Hope you pick one up and learn, you'll love it!

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