Gear Box - The viewing side

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Comment by Kevin Zierath on November 29, 2009 at 12:56pm

Thanks! .. A frozen turkey rolling around banging up my new truck was the motivation. No plans, I just measured the inside width of the cargo area rubber mat. I used 3/4 thick birch ply and pine. its 40" wide, 21" deep, and the sides are 13" high, front and back sides are 7.75 high. The bottom was cut 21"x38.5", sides are 13"x21", front/back sides are 38.5"x7". I used a 2" forstner drill bit to cut the curved handle holes and a jig saw to cut between them. I used a popcorn can to mark the curve of sides (top) and cut them off with the jigsaw. I rounded all the top edges with a 1/4 round off bit on my router table. The inserts are 3 separate pieces, two "T" 7" high pieces, and one 4"x13" short piece. The "T"s consist of one 7"x12" and one 7"x19.25" board centered. The short piece is a good tight fit and hold the "T" sections in place. All pocket holes are on the sides of the wood one would not see when it is side the cargo area of the FJ. I'll post pictures of the inserts.