TruckBox 2.0
Hi, all. I'm building a solar-powered mobile workshop in the back of my truck. It's to be the Command/Service Module of ZAMES, the Zombie Apocalypse Mobile Escape System (the other half of the system is the '76 Shasta 2250 camper I'm rebuilding, also to be solar-powered, for full-timing off-grid).
When it's finished, I'll be able to run all my tools without having access to shore power. It's made out of 1-by poplar boards, with the roof and sides being strip-built, like a canoe. The sides will be clam shell-type doors, covering my hand tools. Mechanic tools in the right side box, so if I need to fix something on the road I won't get run over grabbing a socket. Hand tools for wood will be on the left side.
In the bed, the front bulkhead will hold the electrical panel with the charge controller and a 2000-watt inverter, along with its related accessories, fuses, switches etc. I plan to have enough power to be able to run a table saw off the batteries. Underneath the panel on the floor of the bed will go four golf cart batteries. On the bottom of the bed will be a retractable workbench, and drawers for power tools and other things. I will still be able to get 4x8 sheets into the bed by leaving the rear door open, and there will be a sliding cargo tray as well. With the tailgate down I can still fit my 12' Grumman aluminum boat in the back, too!
The roof and rear bulkhead are done, except for some more sanding and coats of Minwax Helmsman Spar Varnish, and some paint on the inside of the roof. You can't really see the color well, since it's a dark rainy day. But I stained the wood with a custom color I mixed out of Saman water-based stain, mixing Raspberry and Paprika to get as close as I could to the color of the truck. It wasn't dark enough alone, so I tinted a couple of cans of varnish with black paint colorant, so each coat darkened it a little more until it was where I wanted it. It's not a perfect match to the metallic paint on the truck, but it's close. Then I'll put a few more coats of un-tinted varnish over that. For the interior I'm using Behr Gloss Porch Paint in Silver Gray.
The 210-watt residential solar panel is just sitting in place, to show where it goes (and to cover up all the varnish runs that dribbled down over the gray interior paint).
I've started making the right-side clam shell door, as you can see. It's framed with curved, 1/8" aluminum straps, with screws going through the aluminum into the back of the poplar strips. Once all the strips are in place, I'll fasten the door in place to form the shape, and glue and fill all the seams to keep the shape. Then I'll sand, stain and varnish it, and add the hinges and locks and seals and gas lift cylinders. I'll post more as it progresses.
When it's finished, I'll be able to run all my tools without having access to shore power. It's made out of 1-by poplar boards, with the roof and sides being strip-built, like a canoe. The sides will be clam shell-type doors, covering my hand tools. Mechanic tools in the right side box, so if I need to fix something on the road I won't get run over grabbing a socket. Hand tools for wood will be on the left side.
In the bed, the front bulkhead will hold the electrical panel with the charge controller and a 2000-watt inverter, along with its related accessories, fuses, switches etc. I plan to have enough power to be able to run a table saw off the batteries. Underneath the panel on the floor of the bed will go four golf cart batteries. On the bottom of the bed will be a retractable workbench, and drawers for power tools and other things. I will still be able to get 4x8 sheets into the bed by leaving the rear door open, and there will be a sliding cargo tray as well. With the tailgate down I can still fit my 12' Grumman aluminum boat in the back, too!
The 210-watt residential solar panel is just sitting in place, to show where it goes (and to cover up all the varnish runs that dribbled down over the gray interior paint).
I've started making the right-side clam shell door, as you can see. It's framed with curved, 1/8" aluminum straps, with screws going through the aluminum into the back of the poplar strips. Once all the strips are in place, I'll fasten the door in place to form the shape, and glue and fill all the seams to keep the shape. Then I'll sand, stain and varnish it, and add the hinges and locks and seals and gas lift cylinders. I'll post more as it progresses.
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