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Old 02-22-2014, 05:29 AM   #1
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South Cackolacky JKU Cargo Tray Build

After seeing the cargo trays that folks had I wanted one. So, after doing some research and determining that they were high I thought I would build my own. I also wanted to do mine in aluminum. I like to “re-purpose” stuff to see if it will work so I started with a Harbor Freight aluminum cargo carrier that fits in the trailer hitch receiver. I also wanted to make mine where it was easy to remove. Cabin fever makes you do stuff!

I posted a couple of pics in the "What did you do to your JK today?". I got asked if I would start a thread. So here it is.

I completely disassembled the tray by drilling all of the rivets out so the individual pieces would fit in my saw.

I then cut the pieces down to make the tray the size I wanted it.

After cutting all of the pieces, I then reassembled the tray using new 3/16” inch aluminum pop rivets.

I made two cross members out of 1” x 2” aluminum square rectangle tubing. I had to cut the cross member that is located towards the back next to the tailgate. You can’t get a solid piece in with a hard top on because of the roll bar. I made a “saddle” to reassemble it once it is installed (the set screws will be replaced with small thumb wheels when they arrive for ease of removal).

The cross member that is directly behind the seat did not have to be cut. It can be installed through the back doors.

The cross members are held in place by wood working table clamps turned upside down. This creates a “pinch” clamp on the tub/top joint. The thumb wheels do not have to be tightened much. This makes the tray easy to remove. I also made four bushings that slide up inside of the tubing so it will not collapse the tubing over time when the thumb wheels are tightened.

I am going to coat it today with bedliner spray so it will be black.

If anyone would like specifics let me know! It was a fun build!

Here are some pics:











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Old 02-22-2014, 05:46 AM   #2
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Very nice work. The clamps look like they work well.

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Old 02-22-2014, 06:10 AM   #3
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Looks great! Nice DIY keep the ideas coming.
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Old 02-22-2014, 06:39 AM   #4
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Nice mod! A good alternative to the expensive carriers
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Old 02-22-2014, 07:20 AM   #5
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Props from SC! Looks great. Thought about making some extra cash with those skills? Side note, where in SC are you?
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Old 02-22-2014, 08:13 AM   #6
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Thanks for all of the compliments. This site is the best. I don't know if I'm good enough to make any money at what I do! I just like to tinker with stuff. LOL! I'm about 20 miles south of Charlotte NC.
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Old 02-22-2014, 08:18 AM   #7
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Great work my friend... Time for a 2-door kit?
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Old 02-22-2014, 09:04 AM   #8
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Thanks for all of the compliments. This site is the best. I don't know if I'm good enough to make any money at what I do! I just like to tinker with stuff. LOL! I'm about 20 miles south of Charlotte NC.
Not far from me, fort mill here.
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Old 02-22-2014, 09:46 AM   #9
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Not far from me, fort mill here.
Not far at all. Not far at all. South side of Rock Hill right off of the interstate.
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Old 02-22-2014, 03:20 PM   #10
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Got the tray coated today with Rustoleum Spray Liner. Came out great. Need tp get it back together and reinstall it. Final pic to come.



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Old 02-22-2014, 03:24 PM   #11
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Great work my friend... Time for a 2-door kit?
How much room between the back of your rear seat and the tail gate? This tray is 22.5 inches wide.
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Old 02-22-2014, 04:29 PM   #12
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Thanks for having me over today Ted. I enjoyed it. Really nice looking cargo tray. Especially weighing in the low 20's.
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Old 02-22-2014, 04:43 PM   #13
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Glad you were able to get by. Good conversation. Post up some pics of that Jeep so I, uh we can see those wheels again!




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Thanks for having me over today Ted. I enjoyed it. Really nice looking cargo tray. Especially weighing in the low 20's.
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Old 02-23-2014, 11:23 AM   #14
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Just got home from work and did the final install. Everything looks good. We'll see how it does over time.

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Old 02-23-2014, 12:24 PM   #15
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Great looking work Dmc1! Looks very OEM quality.
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Old 02-23-2014, 05:49 PM   #16
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Great looking work Dmc1! Looks very OEM quality.
That's because Ted does quality work!
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Old 02-23-2014, 05:50 PM   #17
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Just got home from work and did the final install. Everything looks good. We'll see how it does over time.
Looks great!
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Old 02-24-2014, 09:56 AM   #18
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Great idea to use the already made rack. I was about to do a custom build for mine but now I don't have to.
One slightly off topic question, where did you get the big liner for the cargo area? I work out of mine and hate spending the time to get dirt and sawdust out of the carpet. All I see are much smaller behind the seat ones.
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Old 02-24-2014, 11:57 AM   #19
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Thanks for the compliments. The mat is a OEM mat that you can get straight from Amazon. That is where I bought it. Hope this helps.


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Great idea to use the already made rack. I was about to do a custom build for mine but now I don't have to.
One slightly off topic question, where did you get the big liner for the cargo area? I work out of mine and hate spending the time to get dirt and sawdust out of the carpet. All I see are much smaller behind the seat ones.
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Old 03-29-2014, 01:24 PM   #20
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Started making another tray today. Got it taken apart and cut it to the right measurements. Time to put it back together now.

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Old 03-30-2014, 12:39 PM   #21
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Assembled and ready to paint.

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Old 03-30-2014, 04:12 PM   #22
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Assembled and ready to paint.
When are you planning to paint? I might swing by and watch number two.
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Old 03-30-2014, 05:12 PM   #23
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It will probably be in a couple of weeks. The wind was too much today and they are calling for rain next weekend, plus I have some personal business I have to tend to. I'll let you know.



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When are you planning to paint? I might swing by and watch number two.
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Old 04-04-2014, 03:29 PM   #24
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Rest of the aluminum showed up along with the clamps. I'll finish fabbing everything and it will be ready for a home. Pictures to come when it is completely done.
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Old 04-04-2014, 05:34 PM   #25
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That's a fantastic tray. Good work. I'm bookmarking this for later
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Old 04-05-2014, 11:34 AM   #26
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Went out early this morning around 5 am and painted tray number two. If anyone local needs one it is ready to go.




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