Pajero Owners Club of South Africa

This is a repost of a project I did in early 2008

The original intention was to create a packing system that would add a second floor to the back of the Pajero on which I would install a fridge slide, and under which I would have space for 4 wolfpacks. My reasoning behind this was that I wanted the fridge as high up as practically possible. Even though this makes getting INTO the fridge a little more difficult (the Pajero does have a nice step on the bumper though) you can't pack anything on top of the fridge so there's a lot of wasted space. The flat floor gets round the wheel arch space problem as well. In addition I wanted the fridge slide to be relatively easily removable as it would often get in the way if I want to move something fairly big.

I wanted to fit 4 wolfpacks, but unfortunately they won't fit, so instead I settled on a combination of 2 wolfpacks and 2 gommoboxes. These will be supported by a single slide with tie-downs to allow some flexibility should my requirements change. I also didn't want drawers as such as swambo prefers to pack boxes in the house and we just load them when packed.

I discussed my design with various 4x4 accessory places like Safari Centre, LA Sport, 4X4MW etc, and the quotes varied from R6900 to R8700, all for systems which never really suited my requirements.

Although many people build their packing systems out of wood, or steel, I opted for aluminium because I wanted to keep things as light as possible. In addition Maizey Plastics produce "Connect-It" connectors, which I thought I could use instead of welding things together. Some people do express reservations regarding the strength of it, but I thought it would work considering some of the commercial offerings use them as well. Disclaimer: - I am NOT an engineer, and time will tell on the merits of this choice (and any other design choices I made).
The Pajero has 4 heavy duty tie downs in the back and I thought I'd exploit the 10mm bolt-holes into which the tie-downs are mounted. I hate drilling new holes into vehicles and this arrangement suits me fine.
The picture below is of the basic frame, checking for fit before I started putting it all together.
The frame is now complete, and the rails installed. The two little "arms" are the supports for the wooden covers to neaten everything up. The bottom left (in the picture) "subframe" is where the fridge slide will be bolted onto (you can see the holes for the 10mm bolts).
The frame inside the Pajero. You can see an additional frame on the left hand side. This is to support the flooring which goes over the wheel arches. The idea is that the wooden flooring covering these is removable so you can tuck small things out of the way. I had intended to mount the compressor inside the gap, between the wheel arch and the door but my Max Air compressor is too big.
OK, just some detailed shots. Below is how the Maizey Connect-Its work. The bit that slides into the aluminium has a small hole. The idea is you whack a punch into the aluminium where the hole is. The resulting "dent" hold the connectors in place. I didn't like that idea for the verticals so drilled straight through the connectors and used 8mm bolts instead.
This is the Connect-It brace piece.
The shot below shows the bracket for bolting the whole shebang to the floor of the Pajero.
And this is now where I'm at. The completed frame from the back, together with both the side pieces. You'll notice i added some braces to add some lateral stiffness.
I have cut all the materials for the fridge slide and the draw itself. I had intended to bolt all that together, but I enlisted the help of someone at UCT to weld that up for me (so will cost me a couple of bottles of my best Pinot Noir)

So ..... more to follow soon.

So here's an update on my packing system. The frame for the drawer itself is complete, as are the two frames for the fridge slide.

I built these frames from 50mm aluminium angle. If it was from steel, maybe I could have gotten away wiht something smaller, but it's pretty robust, hides the slides, and strangely, is a little cheaper then smaller profiles from other vendors.

This is just a general view of where I am at now. The slides and everything haven't been screwed together yet - things are just resting in place
Slightly closer up view of the fridge slide. The fridge will be held in place with turnbuckles inserted into holes in the frame.
A close up view of the corner of the fridge slide
I'm thinking of anodising the aluminium that will be visible for after all the woodwork is in place. So if anyone can suggest a good place in the Montague Gardens area (and know how much this is likely to cost) please PM me.

My next steps are to attach all the trays and frames together, get the wood (never got a chance today) and carpeting, and chop those into the right shapes.

More to follow...

Ok, I have made some more progress on my packing system. Things have gone slower than expected. Work, study etc always seem to get in the way.

The framework was completed a while back and this is how it looks now with the plywood installed, and cut to shape.
The gap between the draw and the edge on the right was measured perfectly when in the vehicle, but as always, something becomes a little misaligned when it's all put back together , so will have to shave a little off there. On the left are two hella's and a standard ciggie lighter socket. Above those will be a Brad Harrison for the fridge (detail below)
The aluminium plate which houses the plugs will form a common ground to make wiring a little simpler, but will be covered with carpet so you don's see it.

Just some detail of the fridge slide, bolted down with 8 10mm bolts. The idea is that the fridge slide be easily removable if I need to.
So pretty much all that is left to do is glue down the carpet (proper car carpet, sourced from Kehls), install the handles and locking mechanisms.

I have yet to find something that works for the fridge slide. I had the idea of using a patio door lock (where it goes into the floor), but can't find one where the main housing is small enough, the bolt long enough, and that doesn't require a key. I'll perhaps have to make something up that is spring loaded.

So, I'll start the carpeting today, and it should be finished during the course of this week.

I wish I could invest in a real workshop , but I'd have to buy a decent house first....

Anyway, I have finished the carpeting, and am pretty pleased with the results.
In the background you can see the fridge slide which will be installed tomorrow. Really, all that's now left to do is actually install it in the vehicle, and connect up the electrics.

I'm still toying with aluminium tie down rails on top, and I'll put an aluminium strip along the front edge to avoid the front corner getting damaged.

I have finally finished

It's taken much longer to get this project done than I originally thought it would, but tadaaaa!
This is just an overall view from the back with fridge and drawer out
And from the side
And a view from inside. Not much clearance between the door and the fridge handles but it worked out OK. You can see how I've secured the fridge to the slide using turnbuckles.
I couldn't find any mechanism to keep the fridge slide closed that I was happy with, so this is my simple DIY solution which works pretty well.
I've decided not to put any tie down rails in yet until I've been on a couple of trips with it, just to see how best to approach that.

But that ladies and gents is pretty much it. The attachment is the cost breakdown - R2200. Certainly could have been cheaper if I'd tackled it in another way, but still way cheaper than the commercial stuff.

Oh, and it got christened on Friday night - while working on the electrics, I knocked my beer over , so my brand new carpet smells of Windhoek Lager Nothing carpet powder didn't fix

Hi Simon,

Surely like this system of yours. I will try it myself now.

Anything you learnt while building the system?

I will look on the internet to find this Maizey plastics and where to get hold of them. Hope I can find them up here in the noth.

Wilfred

Wilfred,

I should imagine they are JHB based. Refer their tel. number: 086 1100 420.


Very nice job there, Simon. Most professional.


-F_D

If I remember correctly from their website their is a branch in Pta West.

Thanks,

I found them in Pta West, will go there soon !!

Wilfred

Wilfred Moore wrote: Anything you learnt while building the system?

A couple of things...

• It has developed an annoying squeak which I can't find... possibly somewhere with one of the joints but I don't think so, it seems to be more metal on metal.
  Also, the layout of the electrical sockets doesn't work. I can't close the door when there's something plugged in. I have to think about how I'm going to redo that part, but it's likely to be a socket box next to the door pillar

Otherwise it has worked extremely well and is still in one piece