JLU Trunk Floor Box

[gevo1]

Hey all,

So I finally got around to an idea I had for a long while. Turns out, others have done similar things but nothing has been available for sale. So, I decided to make one myself since I plan to add/make an on-board air compressor system and this would be the perfect location for it anyway.

Plan is to make a larger storage box that's relatively easy to install, without major modifications and without a major price tag or time consumption.

In my case, I wanted to maximize storage capacity and was willing to make minor/necessary and sometimes already existing modifications to improve storage capacity without significant sacrifice. After much thought and design, keeping complexity down to reduce fabrication time/price, I came up with this (what I hope to be) solution:

Per design requirements, minimal trimming and modification is necessary while maximizing capacity. Firstly, you'll need to trim the forward corners to "square" it off. Its very easy to do as these corners are only single layer and don't involve cutting into the conjoined/epoxied multi layer sections.

Secondly, will be the exhaust. You do need to get rid of the factory "suitcase" exhaust. However, I did not want an exhaust to end pre-axle, so I designed this to clear the Magnaflow Overland Series cat back exhaust. I believe similar exhausts will work as well.
Link to specific exhaust: https://www.magnaflow.com/products/...nd-series-cat-back-performance-exhaust-system

Lastly, you will need to add a 1.5" rear factory sway bar spacer. If you already have a lift of at least 2", you will benefit from this anyway and it will increase the capacity of the storage box significantly.
Link to spacers:

https://www.synergymfg.com/jeep-jl-rear-sway-bar-drop-brackets.html
OR
https://accutuneoffroad.com/product/accutune-jeep-jl-rear-1-5-sway-bar-spacer/

Fitting the new box would require adding silicone around the perimeter (similar to the factory) and replacing the factory 4 bolts holding it in. Although, I'm sure you can use a thin rubber gasket instead to make it easily removable for future access/maintenance projects.

Additionally, storage box is designed with extra clearance clearance in mind for varying track bars/sway bars/exhausts, although this takes away a bit of capacity, I believe the trade off is worth it as it would be more universal.

I'm awaiting quotes for fabrication services since I don't want to fabricate this myself. Depending on how things go, I may change the design for different fabrication/assembly methods. If all works/fits well and others show interest, we can potentially put together a group buy. I'll update this thread as I go along and time allows. If anyone is seriously interested please let me know.

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[3arl0fBruce]

What materials are you planning on having it fabricated from? I would think a heavy-duty 3D print would be sufficient, as I think the existing storage box is just thick plastic.

 

[gevo1]

What materials are you planning on having it fabricated from? I would think a heavy-duty 3D print would be sufficient, as I think the existing storage box is just thick plastic.

Likely 6061 Aluminum sheet approximately 3mm thick. Hence, the square look.

The factory, although resilient, is made of reinforced fiberglass type plastic. With the new box being much larger, it will need to hold more weight and not risk melting from the exhaust.

 

[shagles]

Very interested to see how this turns out. I've wanted to do this since i bought my jeep but lost access to a sheet metal shop a few years ago.

 

[Terrymo]

What materials are you planning on having it fabricated from? I would think a heavy-duty 3D print would be sufficient, as I think the existing storage box is just thick plastic.

Asking because I don’t know. Wouldn’t a 3D printed object of this size potentially have layer separation from heat and vibration?

 

[gevo1]

Asking because I don’t know. Wouldn’t a 3D printed object of this size potentially have layer separation from heat and vibration?

Correct. It wouldnt be strong enough either. In addition, it would be very expensive to 3D print something of this size which would also make it quiet expensive, requiring an industrial size machine to do so.

At this time, best option is cut, bent and welded aluminum sheets. Steel would also work and reduce costs but will be heavier. If costs become prohibitive, I will redesign to allow corner bends and possibly self assembly with riv nuts and epoxy (this would dramatically reduce shipping costs as well)

 

[Terrymo]

Correct. It wouldnt be strong enough either. In addition, it would be very expensive to 3D print something of this size which would also make it quiet expensive, requiring an industrial size machine to do so.

At this time, best option is cut, bent and welded aluminum sheets. Steel would also work and reduce costs but will be heavier. If costs become prohibitive, I will redesign to allow corner bends and possibly self assembly with riv nuts and epoxy (this would dramatically reduce shipping costs as well)

I would be interested except my aftermarket exhaust would likely interfere. I think it’s a great idea though.

 

[gevo1]

I would be interested except my aftermarket exhaust would likely interfere. I think it’s a great idea though.

If the exhaust retains the middle section under the factory cubby, it absolutely will not work. If it exists straight out of the Left side like the Magnaflow, you will likely be ok.

 

[3arl0fBruce]

Correct. It wouldnt be strong enough either. In addition, it would be very expensive to 3D print something of this size which would also make it quiet expensive, requiring an industrial size machine to do so.

At this time, best option is cut, bent and welded aluminum sheets. Steel would also work and reduce costs but will be heavier. If costs become prohibitive, I will redesign to allow corner bends and possibly self assembly with riv nuts and epoxy (this would dramatically reduce shipping costs as well)

Thanks for the info on the 3D print limitations. If heat is an issue with the exhaust, wouldn't the aluminum also transfer that heat to whatever is stored in the larger cubby? Not a deal-breaker, but certainly a consideration when figuring out what to store there.

Even if you aren't successful getting a group buy together for fabrication, I would still be interested in the design and dimensions if you are willing to distribute.

 

[gevo1]

Thanks for the info on the 3D print limitations. If heat is an issue with the exhaust, wouldn't the aluminum also transfer that heat to whatever is stored in the larger cubby? Not a deal-breaker, but certainly a consideration when figuring out what to store there.

Even if you aren't successful getting a group buy together for fabrication, I would still be interested in the design and dimensions if you are willing to distribute.

Of course. Yes heat can be a factor. However, with aluminum, you don't run the risk of melting things (the factory cubby has had incidents of melting). Plan is ultimately to add trimmed pieces of the factory heat shielding anyway. Alternately, the exhaust portion there can be wrapped.

Let me try with the group buy first as that will reduce costs for everyone. Remember, Im still in the process of making an initial testing unit which may require changes

 

[Wild Wild West]

I'm very much interested in this because I wanted to add an auxiliary heater back but the factory bin is plastic and I wasn't sure how to do it. This is a great idea.
I'm not sure I would work out in a group buy though, shipping to Alaska would likely kill any savings from the group buy. I do have access to a great sheet metal shop locally so if you were interested selling the plans I would be interested.

 

[gevo1]

UPDATE:

Improved CAD design for manufacturing and shipping multiple units, stacked to reduce costs.

Material selection is 2mm thick 201 Stainless Steel, bent, formed and welded together to be waterproof and powder coated satin black.

No extra holes, nor drain port will be added. This is so everyone can customize it to their needs (in my case I will be adding an enclosure for a 4 tire air pump system and will drill my own holes for wire glands)

Pricing estimates so far looks like it will be around $550 excluding shipping.

I am awaiting on the first test model to confirm fitment and function before processing larger order.

 

[gevo1]

First test unit has arrived!

 

[Terrymo]

First test unit has arrived!

Very cool. It doesn‘t take much effort to have an idea, and we see a lot of ideas on this forum. The uncommon thing is a good idea and the person actually following through on it. Good for you.

 

[Cips]

Great idea! One thing I learned quickly is how little storage is in these Wranglers.

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