Alright guys, this is my first DIY project for my beloved FJ. Introducing..
- I'm tall (6' 1" - 6' 2") and I want to be able to sleep COMFORTABLY in my FJ on camping/exploration trips. The floor in the FJ does not go completely flat as there is a bump right where the rear seats meet the floor in the cargo area.
- Plywood, stacking blankets, etc. None of which really do it for me or allow me the full use of the length of the FJ.
Now, I'm a touring musician and instead of paying ungodly amounts of money for ATA flight certified hard cases for our gear (we were in a van, not a plane), my bandmates and I made our own. In doing this, I learned quite a bit about the polyethylene foam industry, especially buying thick, sturdy, foam in large quantities. Along the path I got pretty darn good with a hot knife (tool for cutting foam, etc.) With that said ..
- I'm going to fabricate a modular, two or three piece polyethylene foam insert that will not just provide a flat, level, comfortable sleeping surface in the back of the FJ, but with the rear seat cushions removed and front seats moved forward, will add an additional 1 - 1.5' of headroom for us taller people, effectively creating a comfortable sleeping space for two adults of the 6' 2" or shorter persuasion or one adult of a larger size.
It will be two or three pieces, which are waterproof (the nature of this foam takes care of that), further padded, and covered in a zip-up, washable, jersey knit (think pima cotton t-shirt material) cover (available in matching colors for our respective FJs). Each piece will secure to the truck with the factory tie down points and will connect with each other module of the system with velcro. When not in use, they will stack and interlock forming a faux floor in the cargo area while allowing the full use of the rear seats. Granted, it will reduce some of the cargo capacity in the trunk area, but that's why we have roof racks and back seats =)
I'm picking up an order of foam from my distributer this weekend to begin working on the prototype. I'll put up design mockups I did in illustrator tomorrow when I get home.
Now, I'm posting this mainly for the purpose of getting feedback on design before I get to cutting this foam. What would you guys want? Integrated head rest/pillow? Access to the rear compartments and electrical outlets are a given, etc.
I'm going to build mine, put up photos and a real world test report (my girlfriend who hates camping because of sleeping on the ground or on an uncomfortable air mattress has agreed to test it with me and give an honest impression), and if enough people are interested, I'll put together a few demo units at cost to send out. Should those be met with good feedback, I'll begin selling them.
So, thoughts? Thanks!