This project started when we finally got fed up with stopping for tea and a pee and having to unload the toilet of chairs and outdoor stuff so we could use it. I also bought Sandra a sun lounger for Christmas which wouldn’t fit in the toilet anyway. A box was needed at the rear. First job was to measure and think, think and measure. The chairs and sun lounger needed height and depth. There was plenty of width. Constraints were the cycle rack and the two bar / bumper. Eventually I came up with a plan, which involved moving the cycle rack up a little, along with some modifications as to how it worked. The cycle rack used to have a mechanism to lower it away from the van to make loading bikes easier. This had already been removed, but what remained still too up vertical space to operate it. I had to shorten the cantilever legs to give the box more room. The box had to be shaped to fit the back of the van and sit on the tow bar for support. It also needed support at the top, so the raised cycle rack became integral to the top support for the box. The box was to be plywood and clad in stucco aluminium sheeting. Sourcing aluminium was an issue but eventually it came delivered along with 2 large wooden pallets which would burn, if nothing else!! Here is the box taking shape, and then sprayed in Hymer colours and fixed in place.
Special features of the construction included removing the existing number plate lights and moving the reversing camera. I also had to commission some legs to bold to the tow bar to support the depth of the box and re attach the bike rack with a stronger bracket about 21/2″ above its previous position using a different bracket but existing holes. I used a trailer bar to source new rear lights and plugged that into a re-sited trailer lighting socket. I also used window security bolts to hold the door shut. It is sprayed with RAL 9001 cream and Merc Smoke Silver stripes. Inside I can store the 3 chairs, 2 sets of leveling chocs and various pipes and collapsible buckets and bowls – light stuff we don’t need often. The chairs come out as part of our arrival routine, along with chocs if we need them and anything can easily be put away at night. I’m well chuffed with it altogether! 🙂