New Custom rear box / bed

[pastor@southwestbaptist.o]

I am waiting for a new controller from scottyb. So I took the last couple evenings to make rear box.

I thought I would share it here.

I have had rear flip seats before and was disappointed with a few things

1. Noisy when in motion (rattles and flopping on bumps
2. Seating was limited ( I have six kids LOL)
3. Most are either flatbed (no sides) or with sides (but non removable)
4. Access to the motor cover / panel was impossible.

So I set out to make a wooden box that would have three sides that fold down.

I had a local welding shop make up some aluminum supports that bolted under the factor seat bracket. With this set up it raises the seat backrest 4 inches. But I actually like it. (I am 6' 5"). Also I will have to trim and re-drill the rear roof supports. I actually like the basket behind the seat and also the easy access to the motor cover panel.

The box is made from standard 2x8 pine sides and 3/4 inch plywood. Everything was double stained.

I used velcro and foam rubber for the side panels. Very quiet and the velcro is amazingly strong.

The rear gate is held in place with a simple wood swing latch. I wanted the back to operate independent of the sides. So the kids can sit on the sides of the box and have some lateral protection with the rear gate up.

I love that fact that I can have a flatbed or a box. And the kids can sit if they want.

I am happy with the outcome.

I will post some pictures in the next posts.

[pastor@southwestbaptist.o]

Here are some pictures

[pastor@southwestbaptist.o]

I haven't bolted it to the aluminum rails yet.

[JohnnieB]

The aluminum C-channels look fairly sturdy, but it is a cantilever system and you will be hauling very precious cargo, so I'd do some overkill and add some additional support about midway out to the end.

There is a fairly heavy frame cross member at the rear of the bag-well that I inserted an eye-bolt through a preexisting hole and use it to lift the rear of my cart with a chain hoist, as well as the springy thingy I use when I fly a flag low. (See attached)

I've been thinking about adding a home brew box to my cart and using that frame cross member for box support along with incorporating a flat panel into the support for displaying a LSV triangle.

[pastor@southwestbaptist.o]

I think...hope... that the c channel is enough. It seems very sturdy. 1/4 aluminum with welded ends.

I like the lifting eye idea!

[JohnnieB]

View the C-channel as a teeter-totter (lever arm) with the rearmost mounting bolt to the cart frame as the pivot point (fulcrum). It is hard to tell in the pictures, but it looks like the box end has about a 3 to 1 mechanical advantage trying to pull the front mounting bolt through the 1/4" aluminum.

I'd use a Grade-8 bolt and the largest diameter steel fender washer available at the front of the bottom rail of the C-channel, trimming it to fit as needed. (Plus some support of some kind as far towards the rear as possible and practical.)


The thing to remember is the front of the C-channels will try to go up when the box is pushed down.

[Clemsoncartguy]

Yep it will have some lever action esp when you get 200# in there and going over bumps.