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
Key:
3W = 3 way all at 90 degrees
4W = 4 way 90 degrees and Tee
3Tee = 3 way Tee
