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Aluminum Rear Door Storage

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313 views 10 replies 6 participants last post by  njvagabond  
#1 ·
Transit Folks,

I've long been searching for the perfect rear door storage box - ideally to snuggly fit my Traeger Ranger pellet grill and accessories. I couldn't find one that was able to tick all of my boxes - so I designed my own.

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Box is 24" wide by 36" tall by about 15" deep with a single adjustable shelf inside. Front weather tight door folds down on gas springs - with extendable legs that also fold out from the door such that the door acts as a table/bench.

the 'lid' for the legs is perforated with a pattern of mounting holes for other items. Both the main weather tight door and leg lid are lockable.

Original plan was to manually remove the grill from storage and place it on the lowered table - but I've gone the extra step of installing short linear rails on the door with stops on both ends to prevent the grill from over-extending. Slid all the way to toward the van, the door (with grill attached) can simply be closed. Extended away from the van it provides just enough prep surface for right handed people.

With the rear van door open at 90°, the table/bench forms an "L" with the van and keeps the grill master closer to the action just outside the sliding door.

I had a few produced to minimize fabrication cost, and now 3 people who wanted one have backed out (in fairness, it took me a while to get all of the details right - so no hard feelings that they needed to 'move on'). I've listed them on Etsy if anyone is interested. Right now, I'll only ship within Canada as I don't have time/energy to figure out how this aluminum product will be tariffed entering the US.
 
#4 ·
the IP Rating of that box is only 20. google gave me this:
"An IP20 rating means an enclosure is touchproof and protected from solid objects larger than 12mm, but it offers no protection against liquids. This makes IP20 products suitable for dry, indoor environments with low moisture, such as living rooms and bedrooms, but they are unsuitable for areas exposed to water, like bathrooms or outdoors."
 
#5 ·
Yes - I did consider practically every kind of “box” that I could find. Some were not weather tight, some were checkerplate and flimsy, very few had the door folding down. Zero had integrated legs. The OX Box is probably the closest - but it was not quite big enough and the cables supporting the fold down door meant one could only access any kind of grill from the back.
 
#8 ·
Actually, they're super cheap linear rails - way below what one would choose for any sort of machining. But certainly more expensive than drawer slides. I wanted to keep the box as shallow as I could - and Accuride style slides were too tall to put completely underneath the grill, and 'got in the way' if I put them front/back. My mistake in using super-cheap linear guides is that the current guide blocks do not have captive bearings - i.e. if I slide the grill off to perhaps place on a nearby picnic table, all the bearings fall out 🤨. So the forthcoming upgrade will replace just the bearing blocks that can actually hang on to their balls.