Space for Africa

This aluminium packing system, says Adam Stander, is just the first of his DIY plans for his 1998 Toyota Prado. 

Last year I bought our family’s first 4x4, and to make our bush holidays as comfortable as possible, I decided to get a packing system that goes in the back of the Prado’s loading bay.
Another reason why I decided on a packing system was because I first wanted to see if the whole family would be as enthusiastic as I about camping.
A bundu trailer or off-road caravan can be an expensive white elephant if the other members of the family decide they actually prefer the comfort of brick walls.
But after I saw how much a normal packing system costs, and because I enjoy working with my hands, I decided to rather build one myself.

Initially, I considered building it from wood, as it’s inexpensive and strong, but the disadvantage is that it’s heavy and takes up too much space.
Steel too is heavy, but easy to weld.
Aluminium, on the other hand, is light, but expensive, and on top of that I can’t weld aluminium.
Nevertheless, I popped into a scrapyard and came upon quite a bit of aluminium sheeting and angle iron that I purchased at a reasonable price.
After giving it some thought an idea came to me to assemble the packing system using rivets.
With just a basic plan in my head, without measurements or details, I got started and made the packing system fit in the Prado as I went along.

This is what I did:

1. Make some space

First I removed the Prado’s rear jump seats and used their anchor points to bolt the frame of the packing system onto the vehicle.

2. The frame

I cut a large aluminium sheet to fit like a lid on the frame. It was also riveted to the frame, and then I bolted the whole structure into the loading bay.

3. It’s on top

I cut a large aluminium sheet to fit like a lid on the frame. It was also riveted to the frame, and then I bolted the whole structure into the loading bay.

4. Space for more and more …

To use the space behind the wheel arches, I put two flaps in the aluminium lid.
I cut holes in the loading surface and attached the cut-out sections with hinges.

The following fit in this space:
a spare fan belt and water pipes, hammer, axe, wheel spanner, gloves, high-lift jack base, two cans of wheel repair foam, tie-downs, a small toolbox with fuses, wire, cable ties, tyre repair kit, electrical extension cord (20 m), a five-socket plug, and four light raincoats – and there’s still space for more.
I also store my high-lift jack between the fridge and the back seat.

5. Blessing in disguise

The packing system has two aluminium drawers (96 cm long, 44 cm wide and 21 cm high) that open and close on slides.
Originally I hadn’t made provision for ammo boxes in the drawers (two large ammo boxes next to each other don’t fit between the wheel arches).
While I was assembling the system, I found some smaller ammo boxes that fitted in the drawers, but unfortunately they were about a centimetre too high.
To accommodate them I extended the frame by 1 cm, and now three of the smaller ammo boxes (44 cm x 31 cm x 21 cm) fit in each drawer.

6. Storage for folding tables

I put another aluminium sheet on top of the packing system, with a gap of just over 3 cm between them.
Apart from creating storage space for two folding tables (that I also made out of aluminium), it is also the base onto which I fixed the slides for the fridge sliding drawer (see point 7).

Folded, the tables are 3 cm high, and when opened up they form a surface of about 1 m². When the Prado is packed, the tables can be completely or partially pulled out to serve as a work surface.

7. Cool as a cucumber

The most expensive part of the packing system was the sliding drawer for the 80-litre double-door fridge. I built the drawer from heavy-duty slides (about R600) and pieces of aluminium angle iron. I also attached two sliding bolts (they look like levers) to ensure the sliding drawer stays put.

But wait, there’s more

Nadat ek die pakstelsel gebou het, was ek so geïnspireer dat ek
sommer nog ’n paar nuttige goed gebou het.

8. Spadework

I removed the plastic panel on the inside of the Prado’s back door and replaced it with an aluminium sheet and a sheet that folds out – wide enough for a camp stove. I mounted my camp spade beneath the sheet.

9. Hang ’em high

On the inside of the Prado’s roof I mounted a frame into which a steel basket slides. The basket, similar to a freezer basket, extends to just above the fridge and can store four sleeping bags, pillows, small blankets and a camp light.
I’m already busy with a lighter design that’s easier to move in and out.

10. Shade in a jiffy

The entire packing system (excluding the awning) cost me less than R2 500.
The only new components I had to buy were three sets of slides (two for the drawers and one for the fridge), two handles, two locks, four sliding bolts, four bolts, and rivets. The rest were made from scrap material. Similar packing system are retailing for more than R10 000.
With the tables, the packing system weighs 69 kg.
My biggest worry was whether I would be able to remove the whole thing, as the frame was made to fit almost to the millimetre.
But if I turn it by 45º, I can remove it and put it back in on my own – although it’s much easier if two people are doing it.
By the way, I’m constantly refining and improving the packing system.
If things don’t work the way I think it should, I will keep on working at it till it does.

The next step is a roof rack for the Prado and a rooftop tent – which I’ll make myself, of course.