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Old 02-18-2008, 02:04 PM   #2 (permalink)
Fjamming
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Re: More room for your FJ: Rear Panel Tray

So here's how I did it.

Open the rear hatch and pop the window open. Make sure the hatch is locked into place. You'll need to exert some force later.

Remove the 2 screws in upper left and right corner. Pop open the dust shield by the window. Use a flat screw driver and pop open the cap for the 3rd screw and unscrew it.


Use a flat screw driver or pry bar and carefully find a loose space somewhere in the inner edge (where the hinge meets the body) and start to pop open the retaining pins. There are about 12 or so (sorry can't remember). There are quite a few on the top portion so if it's not loose, keep trying. Be careful, those pins are fragile and can be destroyed. Lift the panel through the window when the pins have been pulled.



Be careful about the white pins. They can get get lost easily. Remove them from the panel for safe keeping.





These are the materials you'll need. I got them at Ace Hardware, but you can pretty much get them from anywhere. I got some extra screws because I was experimenting. They are 1/4 inch hex screws of various length (1", 1.5", and 2"). 2 bushings, 2 spacers (1/2"), 2 T-plates, bag of 1/4" locking washers, 2 chrome tipped screw caps for a finished look.





The hardest part is the measurement. Place a blanket or some kind of protective sheet on the table so you can protect both the panel and the table. Place the tray over the area you want to drill and carefully mark it.

Looks kind of like this when lining up.


Don't cover the hole for the screw (one that was covered by a plastic cap) with the tray. After you lined it up, drill the steel tray first (don't drill too high or it will end up where the panel curves-you don't want that. Look at my finished picture carefully for some ideas. Through the hole on the tray, mark the hole for the panel. You'll be ok as long as that hole lines up.

Here's how the backside looks. Use the 1/4 hex screws (1") for the bracing part of the T-bar. Anything longer and it'll stick too far and hit stuff inside the panel. Notice the direction of the screws. I used locking washers on both sides.




The one screw going the other way is 1/4" hex in 1.5" length.


The other side. A rubber bushing is placed over the top hex screw. This rubber bushing will provide some support for the tray when it's snugged down. The tray will hold it in place once the tray is tightened.




Now we are ready to attach the tray to the panel. With the 8 bolts, this thing isn't going anywhere!
Place a locking washer, 1/2" spacer, and the 1/4" bolt onto the 1/2" The 1/4" 1.5" hex screw. There will be a little bit of stud left over. I used a chrome bolt cap to give it a finished look.


Then simply replace the panel onto the rear hatch. You're done!





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