krazytoy
Adventurer
Yep, That was me. I was in SLC taking a LEED class for work.
The Baja Bus 1994 FZJ80 Build
- Thread starter krazytoy
- Start date
Yep, That was me. I was in SLC taking a LEED class for work.
Claytonburns
Member
if you have time can you put a list up of all your modifications?
such a rad cruiser! i want one!
such a rad cruiser! i want one!
krazytoy
Adventurer
This weekend 3 4'x8' sheets of 3/4" Birch plywood showed up at my house? Not sure how they got there, but they consumed about 23 hours of my time this weekend. I have been planning to build drawers and a sleeping platform in the back since my son and I have been doing some camping and sleeping in the Cruiser and we have some good trips coming up this summer. I had done some research and decided what I needed/wanted, in the past when sleeping in the Cruiser with the rear seats folded up I was about 4" short of being able to stretch out and be comfortable so the sleeping platform had to go all the way forward. I also got some ball bearing 24" drawer slides from Home Depot, when you go over 24" slides they get ridiculously expensive. I also wanted a spot to keep water, I was at the RV store the other day looking at tanks and pumps and figured I was going to spend in the neighborhood of $150 on the tank and pump alone, well I decide to stop by our local farm and ranch store and I found a 15 gallon sprayer made for an ATV, the sprayer has the pump attached to the tank and was exactly the size I was looking for! It is all pre-wired and ready to use, here is the link: http://fimcoindustries.com/LG-15-EC.html. So with an idea in my head I went to work, I understand why these are $1000 if you were to buy one, they are time consuming and tedious. On with the pictures!
3 Sheets to the wind???
The space to work with.
I removed the third row seat brackets and will use these holes to secure the drawers down.
The first cut, all I have is a skill saw, router, sawzall, scroll saw and a grinder.
Here is the box for the drawers.
I routered out for a recessed bolt so it wouldn't hit the drawers.
Everything is glued and screwed with 1 5/8" wood screws.
Just some random shots?
Next I build the Drawers, I wanted a flush face and the box only sits about 1/4" away from the tailgate to make use of every inch possible.
I put the top on next.
Next I put on the face of the drawers and the drawer pull. The pulls are actually recessed tie downs I picked up from Army Surplus for $2.68 each.
The sides have to fold up so you can remove the box. I scribed them to the side panels and added some shelf brackets to the bottom for support. I used 1 1/2" piano hinges for access into all the panels.
I made a huge mess of my garage...
Here you can see the compartment for the water tank, I figure if I don't want the tank in all the time this is a good space for sleeping bag and such.
Last was to add the fold out sleeping platform, it hinges off the water tank lid and folds forward, I had to split it in two to allow it to clear the roof. When folded forward I will hang it from the grab handles for the rear seat.
I HATE rattles so I bolted everything down, I will replace the bolts with Eye bolts upon final assembly.
Here is everything.
I am very pleased with how everything turned out. I finish sanded everything last night, I plan to paint everything next week and put carpet on top of it.
3 Sheets to the wind???
The space to work with.
I removed the third row seat brackets and will use these holes to secure the drawers down.
The first cut, all I have is a skill saw, router, sawzall, scroll saw and a grinder.
Here is the box for the drawers.
I routered out for a recessed bolt so it wouldn't hit the drawers.
Everything is glued and screwed with 1 5/8" wood screws.
Just some random shots?
Next I build the Drawers, I wanted a flush face and the box only sits about 1/4" away from the tailgate to make use of every inch possible.
I put the top on next.
Next I put on the face of the drawers and the drawer pull. The pulls are actually recessed tie downs I picked up from Army Surplus for $2.68 each.
The sides have to fold up so you can remove the box. I scribed them to the side panels and added some shelf brackets to the bottom for support. I used 1 1/2" piano hinges for access into all the panels.
I made a huge mess of my garage...
Here you can see the compartment for the water tank, I figure if I don't want the tank in all the time this is a good space for sleeping bag and such.
Last was to add the fold out sleeping platform, it hinges off the water tank lid and folds forward, I had to split it in two to allow it to clear the roof. When folded forward I will hang it from the grab handles for the rear seat.
I HATE rattles so I bolted everything down, I will replace the bolts with Eye bolts upon final assembly.
Here is everything.
I am very pleased with how everything turned out. I finish sanded everything last night, I plan to paint everything next week and put carpet on top of it.
ab1985
Explorer
That's an impressive amount of work for a single weekend. I spend way too much time standing around scratching my head to get that far in 2 days. 
How much do you think it weighs? Any plans to cut out panels to slim it down?
Oh, also love the idea of hanging the extension from the grab handles. I'll be using that one for sure.
How much do you think it weighs? Any plans to cut out panels to slim it down? Oh, also love the idea of hanging the extension from the grab handles. I'll be using that one for sure.
RMP&O
Expedition Leader
Nice job man!! Probably a weekend better spent in your garage then coming over here and drinking beers with me.
BTW, I may be over your way this week if Jerry's is done with the motor, will bring you the Patrol fuel tank when I head that way. And if you want I can get some quick measurements on the FJ60 tank too?
Cheers
BTW, I may be over your way this week if Jerry's is done with the motor, will bring you the Patrol fuel tank when I head that way. And if you want I can get some quick measurements on the FJ60 tank too?
Cheers
krazytoy
Adventurer
The sleeping platform is right at 72" or 6'.
I figure it weighs in the neighborhood of 150 pounds, but I am not completly sure. I measured the fender height so when it goes in I can tell how much it drops the back. No plans to slim it down, I do plan to do lots of camping and traveling to justify packing around the additional weight. :bike_rider:
Nice job man!! Probably a weekend better spent in your garage then coming over here and drinking beers with me.
I think I would have been hanging out drinking beers, but this was not as bad as trying to do a cut and turn and everything else in a weekend!
I am going to be painting the unit this week and hopefiully getting it back in this weekend. We will see...
Mauka2Makai
Explorer
Something to be said about having the skills and ability to build your own drawers and sleeping platform. Very very Nice. Thanks for sharing, This gives me more motivation to DIY. Looking forward to seeing the finished product.
RMP&O
Expedition Leader
Hey at least we know we can do it in a weekend! While we drink beers and waste time BS'ing... :ylsmoke:
Sleeping platform is going to work out great for the boy. Oh and you too!
Cheers
MCObray
Explorer
Nice work on the sleeping platform. Where size of hinges do you go with the extension for the sleeping platform? 1 1/2 like the side access? And if it doesn't hurt to answer, where did you source the hinges? I've got a Sleeping Platform in mind for this upcoming summer.
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krazytoy
Adventurer
Thanks man, I plan to be in the hammock as much as possible!
Yes, the hinges are 1 1/2" piano hinges just like the sides. I changes one set to 4” door hinges, see below. I got all of the hardware at Home Depot.
Thank you very much; I am glad you enjoyed the read.
I got some more done this weekend; you know the problem with the internet is there is ALWAYS someone smarter than you,
which is why it is so great! So, someone asked me if I had any intentions on making any of it removable and this really got me thinking... So I decided that 95% of the time I am not going to want/need the sleeping platform in so I started doing so research on removable hinges and finally just decided to use some regular 4" door hinges, I will have to knock the pins in and out, but that is not a huge deal to me. So anyway I mortised in 3 new hinges so I can remove the sleeping platform. Thanks
Took everything apart and got it all painted. I covered the main box and drwers with DuPont bedliner for extra protection. Then I went back and laid down two coats of gloss black enamel over evertything. It should have plenty of protection now. I am really pleased how it turned out.
Last thing to do was to re-assemble and carpet the top. I found a real nice indoor/outdoor carpet at home depot for a very reasonable cost. I was about $18 for a 6'x8' piece. I picked up some indoor/outdoor glue and cut all the pieces and glued it down. It matched the existing carpet fairly close.
Glue and a notch trowel are NOT your friend if you have any kind of OCD tendencies...
Got the tie downs back in and I added a piece of fely under the loop so it doesnt make any noise. I hate rattles!
All finished up and ready o be put back in, I'm gonna let it air out for a day or two before I put it back in.
Last thing I did was take my little torch to burn the endges to keep them from fraying out.
krazytoy
Adventurer
Thanks Jake,
I got the slides at Home Depot as well. I believe they are 150 pound rated and are the soft closing kind. They were about $18 for the pair. In my research what I noticed is that once you get over 24" slides they get ridiculously expensive, which is why I choose the 24".
