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Pajero cargo frame/bed

As promised, here is the information on the cargo frame/bed I made for my 2004 Pajero.

You'll find videos on how to remove the seats, how to make the frame and how it went in use:

I've driven over 4000 kilometers loaded up, but only slept on the bed once, no problems encountered.

The cost was around $350 (Australian Dollars)

I designed the frame to the following criteria:

  • Can carry at the same time:

    • Mountain bike

    • Downhill bike

    • Surfboard

    • Hiking gear

    • Surfing gear

    • Beach gear

    • Body board

    • Mountain biking gear

    • Mountain bike tool box

    • Food

    • Esky for cold food

    • Camping gear

    • Cooking gear

    • Spare fuel

    • Water

    • Tyre compressor

    • Carry some of the above in plastic boxes under the frame

  • One person could sleep in it

  • It was light weight

  • The frame/bed could be removed

  • The passenger seat wasn't loaded

  • Can easily get from driver's seat to bed frame

Considerations or changes you may want to make

  • Unfortunately with the frame in, it isn't easy to get to the underfloor storage, but I do only store emergency items in there, such as spare clothes, spare cooking equipment, spare food, spare water etc. so ordinarily there should be no need to get at it.

  • I can't sit up on the bed, I needed a specific height to get my boxes under it

  • I weigh 60 kilos, if you are heavier you may need extra strengthening

  • I left the carpets in my Pajero

  • My Pajero is a 2004 NP 3.2L

  • The two forward most lower legs are different lengths to all the others and to each other

  • To increase or decrease the height you could change the length of all the 175mm sections (x 6 of them)

Material Used:

  • Metal Mate brand Anodised Aluminium hollow section 25.4mm x 25.4mm (1" x 1")

  • Metal Mate brand plastic joiners (note these add 25.4mm to the height or length)

Material Bought from Bunnings Warehouse

Aluminium Lengths/quantity of material bought (Bunnings part numbers E&OE)

  • 3 x 900mm long (no cutting required) Part number 9311059091026

  • 4 x 1200mm long (to be cut to length) Part number 9311059091002

  • 5 x 600mm long (to be cut to length) Part number 1138270

Aluminium Lengths cut to size by fabrication company

  • 1 x 1200mm cut to 1 x 775mm 1 x 150mm 1 x 275mm

  • 1 x 1200mm cut to 1 x 775mm 1 x 150mm 1 x 235mm

  • 1 x 1200mm cut to 1 x 775mm 1 x 150mm 1 x 175mm

  • 1 x 1200mm cut to 5 x 175mm 1 x 150mm

  • 5 x 600mm cut to 560mm

Check aluminium lengths you have now

  • 3 x 900mm

  • 3 x 775mm

  • 4 x 150mm

  • 1 x 275mm note this is adjusted for an error in my build

  • 1 x 235mm note this is adjusted for an error in my build

  • 6 x 175mm

  • 5 x 560mm

Joiners (Bunnings part numbers E&OE)

  • 4 x 3 way T piece part number 9311059700089

  • 4 x 3 way 90 degree Part number 9311059700072

  • 4 x 4 way 90 degree Part number 9311059700102

Feet (Bunnings part numbers E&OE)

  • 6 x Feet (obviously, these go on the six legs!) Part number 9311059700058

Wooden top

  • 2 x MDF 900mm x 600mm x 9mm thick Cut one to length of 850mm

Note if I did this again I would use one piece of wood cut to 1750mm

Where the aluminium lengths are used

Where the joiners are used


  • 3W = 3 way all at 90 degrees

  • 4W = 4 way 90 degrees and Tee

  • 3Tee = 3 way Tee


Dave North
Dave North

What CAD program did you use to draw the frame?

Unfortunately I don't have a computer that I could load CATIA or any other decent program on, so had to use the web version of Autocad. It's very limited in functionality, and I ended up 'drawing' every line, as I couldn't figure the extrusion function but forget why! So basically it's a picture not a model 🤣
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