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  #1  
Old March 6th, 2012, 12:23 PM
chris snell's Avatar
chris snell
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Chris Snell
87 Ex-MOD 110
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Join Date: Aug 2005
Location: Kansas
Posts: 2,439
Lock Boxes

The revival of the Troy box thread reminded me that I never finished the write-up on the boxes I built.

I needed some sturdy lock boxes for the back my early 94 truck. At the time, Troy wasn't making the narrower boxes to fit the early trucks with the roll cage bar that runs across the wheel well. With my brother-in-law manning the SolidWorks console, this is what we came up with:

http://www.flickr.com/photos/defende...7624662190639/

It's a bit narrower than the Troy boxes to accommodate the roll cage but it doesn't sacrifice the wider portion completely. It's not a rectangular cuboid and this makes a big difference when you're trying to pack it full of tool bags, etc. My box also has two rear ports for running cables into the box if you want to mount radios, etc., inside.

The box is a simple sheet metal design: 14 ga. steel, cut with a water jet, folded, and welded together at the seams.

http://www.flickr.com/photos/defende...7624662190639/

The boxes were fabricated by Rapid Sheet Metal in Nashua, NH. These guys do awesome work and they're great to deal with.

http://www.flickr.com/photos/defende...7624662190639/

http://www.flickr.com/photos/defende...7624662190639/

http://www.flickr.com/photos/defende...7624662190639/

I had my boxes powdercoated locally by a shop that specializes in custom bicycle frames. I chose a hammered black finish because it looks great and it's durable.

http://www.flickr.com/photos/defende...7624662190639/

My box was designed to accomodate Tuffy lock tumblers. I ordered a set of four, keyed the same as my center console box. One key opens all of my boxes.

http://www.flickr.com/photos/defende...7624662190639/

Much to Barry's disappointment, my Defender came from the dealer with carpet, custom-ordered by the buyer. The original buyer was a Jewish lady in Fort Lauderdale. Go figure.

The adhesive used for the carpet permanently ruined the paint on my wheel wells so I decided to throw down a layer of Dynamat and continue with the carpet theme.

http://www.flickr.com/photos/defende...7624662190639/

http://www.flickr.com/photos/defende...7624662190639/

I used some high-end German carpet and tacked it down with contact cement. It's held up nicely.

http://www.flickr.com/photos/defende...7624662190639/

At the front of my driver's side box, I installed a marine-grade 12V outlet for my Engel fridge.

http://www.flickr.com/photos/defende...7624662190639/

I used Ancor marine-grade wire and connected the outlet to the Blue Sea fuse box from the Battery Box Redux thread.

The outlet location is perfect It's protected by the roll cage and driver's seat and my fridge has never accidentally disconnected.

http://www.flickr.com/photos/defende...7624662190639/

The finished product:

http://www.flickr.com/photos/defende...7624662190639/
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  #2  
Old March 6th, 2012, 12:52 PM
ipgregory's Avatar
ipgregory
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Ian Gregory
'97 D90 ST #1008
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Join Date: Jun 2009
Location: Henderson, NV USA
Posts: 1,083
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Nice boxes Chris, looks like they turned out very well. Any idea what it cost to have them made, shipped around, coated, etc.?

Isn't that bar removable and only needed for the seats? You can't run seats with the boxes fitted so why did you decide to retain it?

On mine I plan to cut the holes for wires and so on higher up on the box, just below the hinge and in line with the existing holes in the capping. That way I can route the wires inside the capping out of sight and out of harm’s way. I hate seeing exposed wires. Need to keep it ‘Tub Sexy’ so to speak.

Ian
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  #3  
Old March 6th, 2012, 06:42 PM
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chris snell
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Chris Snell
87 Ex-MOD 110
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Join Date: Aug 2005
Location: Kansas
Posts: 2,439
The fabrication on the boxes was $1239, shipped to Colorado. Powder coating was another $250-300, I think. RSM is a high-end fabricator. They are not cheap but they do beautiful work.
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  #4  
Old March 7th, 2012, 01:56 AM
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ipgregory
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Ian Gregory
'97 D90 ST #1008
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Join Date: Jun 2009
Location: Henderson, NV USA
Posts: 1,083
Registry
Monday morning quarterbacking I know but couldn’t you have just removed the bar? Or failing that cut a slot in something like one of Troy’s Boxes to fit around it? I know with my truck improvement budget there are many things I would rather spend the extra $1k on than re-inventing the box so to speak. Especially for that sort of cost increase.

Ian
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