I am designing a custom boot box. Goal is one with a lid sturdy enough to sit on (so I can change into/out of my golf shoes), that lies flush when the seats are folded, yet won't bind when the seats are raised (I have an idea how to do deal with the fact that the seatbacks move back into the boot area as they are raised). If I can find the right material, I plan to cover it with the stuff that resembles the back seat.

I built a prototype out of foam board last night...encountered some gotchas that will change my plan.

All that said, does anybody have any ideas for features? Right now it's a plain box with a removable lid. Don't want to build it and then discover "crap, wish I'd thought of that"...

I'm thinking fiberglass rather than wood (lighter) but haven't figured out how to make the inner mold.

 

Make differnt sized compartments inside to tightly hold a variety of things. Or have removable/switchable compartment walls to rearange the inside to suit the need of the day.

I personally use a milk crate and bungie cords.

 

Options to consider:
- lockable or latched so the top doesn't flap up and down over bumps
- waterproof, so I can throw my wetsuit in it when I steal your design
- removeable
- cleanable
- padding inserts
- line with the soft half of velcro strips so you can velcro things to the inside
- wire a light it the underside of the lid

 

line the bottom with that grippy shelf liner so things won't slide/bang around inside.

 

Yes I have been thinking along the same lines.
The top of the box should be level with the back of the seats when the seats are folded forward. Maybe a folding flap to fill the gap. It should have atleast three compartments maybe adjustable. Needs a sturdy lid because it will become the bottom of the boot. As for materials, how does vacuformed ABS sound.

If this or something like it were avaliable I would buy it in a minute.

 

Latched I had considered. The initial design was hinged but had drifted toward lift off top...but hadn't considered bumps so I'll have to think about that again.

Absolutely. That is one of the issues in that the shape of the interior above the box makes lifting it out a bit of a challenge.

Padding inserts, lights, Velcro...hmm. Hadn't considered those but great ideas. Since the battery compartment is right below it I should be able to rig a light off the battery (note to self: build in a switch on the lid).

Need to find some generic material that can be cut down. Not sure where...

Exactly my plan. I'm thinking the flap can be spring loaded such that the seat pushes it down out of the way as it is lifted. If I go that route I may make it in two parts...one for each seat half.

Yup...original plan was fairly thick plywood but open to suggestions.


Sounds way to hard...If I could figure out how to make a mold, I've been thinking fiberglass.

Not from me. One will be enough for me on my limited availability. I hope to have it done by AMVIV...maybe I can "sell" the design to one of the vendors.