Overhead L-tracks
As an experiment I decided to add L-tracks above the side windows in the cargo area - I've got a bunch of ideas for ways to use them to increase cargo capacity. In this post I'll describe what's involved in adding them and as I implement some of my storage ideas using the L-tracks I'll post those ideas.
There are four 8mm threaded holes behind the cargo area headliner, two on each side behind the clip-in hole covers. In this photo I've removed the covers on one side and the threaded holes are visible:
The covers can remain in place when the L-tracks are mounted, so holes for the L-track mounting screws need to be made in the covers. I made this template to accurately locate the holes.
1. Print templates and verify that the printout is correctly scaled by measuring the ruler printed on the template page.
2. Cut out templates closely along the lines so they fit into the recess in the plastic hole cover plate.
3. Remove plastic cover plates from headliner, center punch the hole locations and drill holes large enough to clear 8mm bolts.
4. Replace the cover plates and verify that the holes are correctly aligned with the threaded holes behind the headliner. It is possible that the holes in the cover plates might need to be enlarged slightly if there are manufacturing/assembly variations in your Grenadier. In my Grenadier, three of the holes lined up perfectly and one was slightly off so I enlarged the hole in that cover a bit.
The surface of the cover plate is recessed about 3/16", so to mount the L-track without stressing the plastic of the covers, 3/16" - 1/4" thick spacers are required. You could use a stack of a few washers, but I made spacers by cutting them out of 3/16" plastic with a hole saw.
Next decide how long you want the L-track to be. The threaded holes in the Grenadier are only about 10 1/2" apart, so for maximum L-track strength, the L-track should probably only be slightly longer than that, maybe 15-16". I decided to make mine longer as a test (24"), with the idea that only lighter loads would be placed on the longer unsupported end of the L-track. I may shorten it later if the extra length towards the back isn't suitable for supporting anything. Also at the front end, the L-track hides the factory mounting slot, so if that's to be used for something else, the L-track will need to be shorter.
The L-tracks get mounted with 8mm machine screws. The mounting holes in the L-track will not match the spacing of the holes in the Grenadier, so you'll need to drill holes at the appropriate distance. I used one of the holes that was already drilled/countersunk in the L-track (although I had to enlarge it to fit an 8mm screw) and unfortunately the second hole fell in the narrow part of the L-track so I wasn't able to use a countersunk flathead screw there because of the large size of the flathead. I used an Allen cap screw there, which means that an L-track clip can't go in that location. Shouldn't be a problem though, there's plenty of length on the L-track for attaching clips.
Once the holes are done, the L-tracks install easily - place a spacer under the L-tracks at each hole location and fasten the L-tracks to the threaded holes in the Grenadier with 8mm flathead screws, 25mm long or so. The Allen cap screw is in the forward hole in these photos.
As I implement storage ideas using these L-tracks I'll post photos. I may do an overhead cargo net first. or possible a storage bag of some kind.
