Hi all!

Thought I'd share my handy work with everyone...

So when I bought my 90 the previous owner had built a nice little unit in the back and had a couple of bench seats either side, a nice setup but none of my stuff fitted in it and it took up too much of the boot space, although me and the misses did cook some dinner in the back of it and sit in it like a tiny camper once!

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Anyways, I started unbolted it all and began with a bit of basic dampening to the panels. I found that every bump I was going over was making the rear panels drum and reverberate. I solved this by adding a bit of weight to the sides by using chimney or roofing flashing bought from B&Q. Three small rolls did the whole of the rear and fitted perfectly in the recesses without too much messy cutting.

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The difference is very noticeable and I'm very pleased with the result, the vehicle is now much quieter, so much so that it's highlighted the creaky rear door - another days job it seems!

So on to the main event... I had a rough plan in mind but short of a bit of measuring and a lot of guestimating it was defiantly a rough plan! I measured up the space between the tubs and worked out the two 50L 'really useful boxes' would fit nicely between the arches only slightly proud of the tops. I found that I'd need to raise the floor level by about 10mm to clear the boxes, I wanted to insulate the arches anyway so I coud do this with the insulation. I used closed cell high density foam matting (basically camping bed roll!) and stuck it in place over the arches. (Sorry no pics of this stage). I then measured out and cut some 9mm ply and lined the arches over the insulation with the ply.

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I screwed the ply straight through the insulation and into the arches using drywall screws making sure I missed the outer supports.

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The 9mm ply is going to be a permanent fixture but the flat top to incase the boxes I wanted to be removable. I cut several pieces of 18mm ply to make up the top, I had to do it in several bits as it wouldn't fit as one bit! There's a long length along the back, a large bit in the middle and a couple of other bits to make up the puzzle and keep everything from sliding about. I placed it all together loosely and drilled through both pieces to add captive fixings into the 9mm arch coverings to hold down the top and make it removable with just a few bolts.

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Getting there!

Next was to start carpeting, I bought 2 metres of anthracite van carpet from a local carpet supplier, this stuff is quite thin and has no backing so it's great for this sort of thing. It came on a 4m wide roll so that gave me 8 square meters... I think that'll do to start with! I pre-emptivly cut the rough shape of the carpet using the 9mm ply as a template, this also allowed me to tuck and glue the bottom floor edge under the ply before it was fixed in place. This stage proved to be a pain in the ass as I'm a bit of a perfectionist and I wanted to get it right. Anyways, I carpeted over the ply and cut out little holes where the captive nuts are, I continued the carpet onto the sides of the vehicle and overlapped the sides as this will get insulated and ply lined later.

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I also carpeted over the back of the bulkhead and up to my newly fitted dog guard. The box in the middle of the bulkhead is for my speakers in case you were wondering, it holds two 6x9's which sit behind the front seats assisted by two smaller tweeters mounted to the side in their own little boxes

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Next was to start covering the top deck. I covered all the bits of the puzzle individually just on the top surface leaving the sides clear as there was not enough gap to allow for the carpet. My fixings for the top deck also double up as very carefully positioned lashing points for my fridge, jerry cans and gas bottle.

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I had to do some slight adjusting of the holes to allow for a nicer fit, but other than that it all went together very well. I also found that I had to add a few more fixings to keep the top deck in place and since I'd already carpeted over the 9mm stuff I had to do a quick trip to screwfix to get some different captive fixings that can be screwed in from the top. :frusty: After the extra fixings were fitted to was all kushty!

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And my 'really useful boxes' fit well. The centre support isn't really needed with the 18mm upper deck but it helps spread any load. It's not fixed, it just sits in with resistance - this turned out to be a good thing as the boxes wouldn't have cleared the boot hinge with out the centre support not moving over slightly when you pull them out

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I just need to add a bit of aluminium finishing around the leading edges and then crack on with the sides... watch this space!! :tea:

Great neat job - providing me with inspiration!!

That look fantastic really well done

Great job,that.
Looks realy good!

Well done, good job done

Looks good Something I'd like to do at some point. So has given me a little help.

Nice job. Something I've been thinking abput for my 110 CSW. Always need neat storage space.

great job, nice and tidy

Very nice that! I like it!!

Any idea roughly how much £££ it was?

Many thanks for posting this. I've been pondering what to do with the load area of my 90 and this is providing me with a lot of ideas and inspiration. However, I've got a flip up seat on the right hand side, so I'll have to figure something out about that one.
Anyway, thanks, keep the pics coming.

Thanks for all the positive comments folks I'm pretty pleased with it if I do say so myself! As for costing... let's see... the ply was about £40 and I've still got the sides to do, I had the timber yard cut it to the rough size so it was easier to handle. The boxes were £11 each, the carpet was £3.50 a metre of which I have used two (by 4 metres) so far, the tie downs were donated by a friend, 3 cans of spray glue at £3 a tin, the insulation was about £6 and a hand full of screws and fixings that were probably about a tenner... so about £90 all in so far, not bad considering that's the sides and the roof lined, insulated and carpeted too - I'll be using some thicker rock wool insulation for the sides and roof and a lighter thinner carpet on the roof that's a better match to the front headliner

that looks well smart

Do like a bit of innovation beyond all the off the shelf bits. Help's Landys' to stay unique to their owner.

looks great. Well done. Are you leaving those screws pointing through the arches or planning to grind them off? Is there a possibility of someone catching their hand whilst changing a wheel or maybe the tyre catching them on articulation when traveling off road?

I might trim them down a bit, there's no way the tyre can touch them so I'll probably just leave them tbh. They'll soon dissappear into a couple layers of schultz anyways

D90mitch said:

Do like a bit of innovation beyond all the off the shelf bits. Help's Landys' to stay unique to their owner.

Click to expand...

+1 A great idea and cheap to by the looks of your costings!

Very nice job, intend to do something similar to the 110 for sleeping on. Thanks for the inspiration.

Alm.

I'll be doing a different setup in my 110, I'm building a second bulkhead to fold down over the rear seats and built in racking accessed by my external lockers .... but... that's another thread....

Back to the 90...

So the load area is now finished bar a couple more tie down points, I ply lined the sides and insulated them using rock wool (used in houses) which just happened to be the right thickness and I just cut it to size.

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I used some aluminium strip that I had left over to make up a couple of brackets to fix the ply to. On the sides I just fixed it behind the other piece of ply and on the rear window I used an existing bolt to secure it, the ply screws into the aluminium with the same dry wall screws. I blanked out the rear windows with a bit of spare carpet as there will be ply over them!

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I continued the ply into the front of the cab up to the edge of the door frame. I fixed it using dry wall screws, I drilled a small pilot hole then screwed through the aluminium of the vehicle.

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I trimmed down the screws with the grinder before tucking in the excess carpet and holding it in place with a bit of glue and the door seal.

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And the other side...

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Here's the rock wool behind the ply panels... should be nice and snug come winter

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I screwed the two rear sections of ply to each other as there weren't many good fixing points in the corner, the section covering the rear window was tricky as it's not at all square

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Once I was happy with the fit I removed the ply and carpeted it before re-fitting. All the fixings are hidden, I cut a little slit in the carpet then screwed through the ply and stuck the slit back down. I think it's neater when you can't see any fixings

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I was going to line roof with some thin hardboard to get the curve in it and insulate it with more rock wool but it was such a pain in the ass and I managed to snap the board trying to get the curve right so I binned it and just carpeted the roof instead!

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