My rear storage solution
So I purchased my 2011 Express last month to replace my 2004 that was getting a little old. I haven't done alot to it yet. Just new Maxpider floor mats, a bug guard, and replaced the passenger side blend door actuator gear so the wife now gets cold air when the A/C is on.
As with my old D I wanted more storage in the cargo area. I never used my third row seats in the '04 so all I did with that was remove the lower bench portion of the seat so I could put tools and the such behind the second row seats.
For my new truck I wanted a more permanent solution. The provided under floor storage is nice, and much better than the '04, but I still wanted more and since I will never use the third row seats, it seemed like a perfect place for a full length under floor box.
So here's what I have done so far:
I removed the third row seats, which was fairly simple. Pop up a couple plastic covers, take out 6 bolts, unplug the head rest electrical connector, and lift them, somewhat awkwardly, out.
Then I took out the factory cargo box, which was just a matter of clips and a few bolts, ending with a nice and empty cargo area.
I put a level across the floor and found that from the rounded bump at the back to the bump in the front was level. So I went and got a sheet of MDF and started cutting. I started by measuring to see how big of a base I could get in the area. I ended up with 34 1/2 x 49, which still leaves room for the second row seats to recline.
Then I measured up to the level of where the sidewalls turn to join the floor and figured out that its angled slightly. (Couple inches difference from front to back)
I then found out that the existing plastic cargo box was also support for the rear plastic trim piece so I had to build that area up to be the back of my new box and support the trim when reinstalled. This was done by cutting progressively deeper pieces of 2x10 and OSB to match the curve of the back of the truck.
I had to add one more piece of OSB on top and drill holes for the 3 plastic circles that support the trim piece and the 2 retaining clips. I also drilled a hole for access to the spare tire winch and counter sunk 2 holes for bolting the box down to the existing clips in the body. I also added the back of the box, cut at a 3 degree angle on top to match the sides of the box.
Then I cut the top to match the contour of the rear plastic trim
To be continued...