After using my ute for the last 2 years with limited space and got bogged few times, I had to come with a more practical, compact with freedom idea... I looked for vans, cars, and decided on a 4x4 with big tray!! So I swap the Thunder for a Rodeo..




I build the shell made of wood (pine) which is light, strong and easy to work with! Then cover the whole thing with 3 coates of polyester (mixed with colour). I did rushed it a little as I had only 2 weeks to build it! At this stage its not 100% finished, almost there.. still the back door, bed on the top to finish..
The concept is as compact as possible but that can still take 4 boards, 5 sails, 4-8 masts, 4-5 wishsbones and have a good size dry bed (110x264cm)!! Thats why I build the bed on the top, nice view and out of the wet gear ;)
Also there is a see through with a 300x300 and 300x600 windows, the shell does not oversize the cab so the aero of the car is not affected ;)
There is 2 side doors for easy access to those hard to get spots!


















The project cost was around 1200$ including a couple of electrical tools!
If you have any questions please feel free to ask on how to :)
I am not a cabinet maker, just someone that can use his hand, so anyone that is practical can make one.. plus the concept is simple!

Nice job!

Top job there samOZ. If you havent yet fitted the gas strutts for the doors, try Martin Trailer Parts, they also have the rose joint balls (ends) at all differant angles to fit the strutts.

Looks fantastic, well done.

Do you have any issues with the rear overhang (registering the vehicle etc?)

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mineral1 said...

Top job there samOZ. If you havent yet fitted the gas strutts for the doors, try Martin Trailer Parts, they also have the rose joint balls (ends) at all differant angles to fit the strutts.

Thanks mineral for the shop tip I will look to it, yeap thats the next step.. I got a pair at home from my previous build (was steal!), but they are too strong!! the doors are light and its pine so I need some light gas trutts!

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JayBee said...

Looks fantastic, well done.

Do you have any issues with the rear overhang (registering the vehicle etc?)

ah ah, thats a good question! I did drive my Thunder for 2 years with the back open and never had an issue with it!
I think it look clean enough, and put that high vis strap at the back and corner..
I just crossed AUS from Perth to Sandy Point 3900kms with it without any drama and be back in 2 weeks.. so we ll see ;)
It is sticking out 240mm which is not too much I think!! for a total of 2640mm..

Love it! Good work!!!

Can you hoist it off with all the gear inside when not in use? If so how is it attached to the tray?

nice sam oz!

forget cabinet making, you should be a chippie,

other than the rare few you'd be hard put finding a frame that straight on any building site these days.

What he said, damn that is neat and tidy and STRAIGHT!!
Oh yeah and the JP's go on the inside not vice versa

You've got the boards in the trailer without bags - what did you use to cover the wood so that they don't get scratched?

Nice work.
How does it attach to the vehicle so it doesn't slide off?

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ginger pom said...

You've got the boards in the trailer without bags - what did you use to cover the wood so that they don't get scratched?

I presume he (Sam) has done it by now, but the best thing I found is pool noodles, cut in half and glued to the timber with liquid nails. I have it all on inside of my trailer.On the end panels, those rubber mats jigsaw styled from Anaconda or such like, they use for tent floors, are also a good option to glue in place, to save any boards bumping or rubbing on end panels.

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FletcHuz said...

Love it! Good work!!!

Can you hoist it off with all the gear inside when not in use? If so how is it attached to the tray?

I thought about it and should have done it first in the build, because the little time I had to build it.. I pass! But I can always add it later, have to do a bit of search on how to.. I saw some people we some caravan hoisted on they ute before.. so yes why not!

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graceman said...

What he said, damn that is neat and tidy and STRAIGHT!!
Oh yeah and the JP's go on the inside not vice versa

your grace, the JP go outside because is the board that getting used less ;)
but for the long road, the booms goes on the top bed and the JP inside...

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Windxtasy said...

Nice work.
How does it attach to the vehicle so it doesn't slide off?

it got 6 heavy duty square bold to the tray (4 corners, 2 centre sides) + 2 centre bold

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mineral1 said...

ginger pom said...

You've got the boards in the trailer without bags - what did you use to cover the wood so that they don't get scratched?

I presume he (Sam) has done it by now, but the best thing I found is pool noodles, cut in half and glued to the timber with liquid nails. I have it all on inside of my trailer.On the end panels, those rubber mats jigsaw styled from Anaconda or such like, they use for tent floors, are also a good option to glue in place, to save any boards bumping or rubbing on end panels.

pretty close mineral ;) I have plenty of 5 mm vinyl left at home, so I used some contact glue and added vinyl strip everywhere is contact with water, sails, boards got 2x (1x across the whole and 2x small bits and each side due to the V shape of the boards), under the frames too. I done this before closing the shell, its much easy access ;)