Explorer Thread!

[giant_mtb]

2x4s if you're gonna be sleeping on it.

[BimmerM3]

Biscuit seems like pretty close to the right color.

If I order two yards, you think it'll come as a single, 80"x72" sheet? Because that would be ideal. I'd probably get three yards just to be safe.

http://www.upholsterysupplyonline.com/products/1655-Bisciut-Flexform-Carpet-80%22-Wide.html

EDIT:

Or this. More carpet less speaker cover.

http://www.upholsterysupplyonline.com/products/9029-Tan-72%22-Wide.html

[giant_mtb]

Probably.

[68_427]

Satin rainbow cheetah sheets from wally world $20 and you'll be crushing pussy

[MrH]

Yeah, get something cool.  Tan is boring.

[BimmerM3]

You're boring.

[Rupert]

If you use 2x6s you'll have the right height by default. I would run them front to back, and cut them at a taper to level off the top where they go over the rear seats, then cut them where the rear seats bend up for removeability (keeping in mind that at 6" tall, the rear seats likely slope back enough to interfere if cut them too close). You could either run two or three located in from the edges, use 2x2s for cross pieces and 3/4 inch ply on top, or you could use two at the edges and use 2x4 cross pieces.

Few considerations might be that 6+3/4+carpet height is almost 7", so you might want to rip the 2x6s to 5" first, that 6" might not leave much room to sit up (I would measure 6" down from the roof and see what that's like), and like you kind of alluded to, the rear seats might not be stable enough to use to support the platform. Would be cool to just have the thing on a piano hinge so you could keep it in all in the back.

[BimmerM3]

I ordered a storage bin that *crosses fingers* should fit well in underneath. So I'm going to wait until that arrives before I figure out exactly how tall it'll be.

Either way, I'll have plenty of room to sleep, but I won't be able to sit up fully, which is why I want to leave the driver-side seat clear.

[BimmerM3]

Phase 1 complete.

[Rupert]

Nice.

[BimmerM3]

I'm actually pretty amazed that the bins fit in there so perfectly. I was planning on using a bin on one side and then just having the other side be an open slot with whatever room was left over, but this is better.

EDIT: Thanks for the 2x6 suggestion, BTW. My original solution was gonna be waaaay more complicated.

[AutobahnSHO]

that's going to be super awesome!

[Rupert]

I'm actually pretty amazed that the bins fit in there so perfectly. I was planning on using a bin on one side and then just having the other side be an open slot with whatever room was left over, but this is better.

EDIT: Thanks for the 2x6 suggestion, BTW. My original solution was gonna be waaaay more complicated.

Yeah, no prob.

I wish all my projects like that would work out that neatly.

[BimmerM3]

Phase 2 complete.

I probably should have used actual plywood instead of MDF, but I got excited at Home Depot and bought the MDF before I really thought about it. If it's not strong enough or gets too messed up from moisture or whatever, it'll be pretty easy to replace. I'll also probably have to sand down the corners a little more if I actually end up carpeting it.

The only sorta issue at this point is that the plastic trim around the trunk is raised compared to the actual trunk floor, so I have to lift the platform slightly to get the bins in and out. Not a huge deal but kind of annoying. If only 2x6s were actually 2" x 6" - the extra half inch would solve the issue completely, I think.

[giant_mtb]

Sand the corners down and be sure it doesn't get too damp and you'll be fine for a while. Sweet camping rig!

[Laconian]

Ooo, MDF. Hmm. Spraying some lacquer on the top might extend the life of it?

What about screwing some rubber spacers into the edges of the 2x6es? You'd get a bit of extra height and it might keep things from clattering.

[Rupert]

Yeah, just fir up the 2x6s to the right height. You can use a 2x4 that you rip to half inch strips or whatever the right height would be. Glue them on and then drill (to prevent splitting) and screw down in a few places.

[giant_mtb]

MDF will soak up so much lacquer or polyurethane it's not even funny, especially on the edges.  Wrap it in duct tape. 

[RomanChariot]

Yeah, just fir up the 2x6s to the right height. You can use a 2x4 that you rip to half inch strips or whatever the right height would be. Glue them on and then drill (to prevent splitting) and screw down in a few places.

This is a good idea but it would probably be easier to just use 1x2s rather than ripping down 2x4s.

[BimmerM3]

I'll probably have enough MDF left over to just use that.

[Rupert]

Yeah, all true.

[BimmerM3]

Phase 3 complete - Explorer is ready to explore.

[Soup DeVille]

Nice. 

[Rupert]

Looks good! I'll be curious to know if there are any rattles after some miles on bumpy roads.

[shp4man]

Really clean Exploder. Nice to see some people taking care of them. 

[Soup DeVille]

Looks good! I'll be curious to know if there are any rattles after some miles on bumpy roads.

Might try putting some weatherstripping around the outside of the MDF platform if any of it contacts the stock interior bits.

[BimmerM3]

Looks good! I'll be curious to know if there are any rattles after some miles on bumpy roads.

Might try putting some weatherstripping around the outside of the MDF platform if any of it contacts the stock interior bits.

Both pieces are pretty snug against various interior pieces, so no issues so far. I might either carpet them at some point too.

Really clean Exploder. Nice to see some people taking care of them. 

Thanks! Though most of the credit goes to the previous owner and dealership who cleaned it up. It was in amazing condition when I bought it.