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Old 09-26-2011, 11:08 AM   #1
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Reunel baja box upgrade

I've noticed more and more Reunel rear bumpers showing up on vans here, so I thought I'd share my latest project....

My Reunel came with the tire carrier and jerry can carrier. After having a few jerry cans stolen, and also dinging up the carrier pretty good (bus tow-bar mashed into it pulling out of a driveway with a steep dip), I wanted an upgrade that would be more functional. I thought about just ordering an Aluminess, but wasn't sure how much work it would be to adapt it to the the Reunel.

I ended up buying an undertruck steel toolbox from Coastal Farm, and welded up a new support frame. One nice thing about the truck box is the opening is double-flanged, so it should be water-tight. And it locks using a reinforced double-pin style latch so it would be next to impossible to pry open. These boxes are meant to mount sideways, but this particular model didn't have anything that would cause issues mounting it upright.

Old jerry can carrier (partway cut off):


Here is the new frame. The box is stout enough I could have probably welded it directly to the swing-post. But I wanted it extra strong, and also wanted it easy to replace i case it gets damaged, or I decide to put a bigger one on, so the box will be bolted to the new frame. And, it was already poweder-coated so I didn't want to ruin that. One consideration in using 2" tube for the lower part of the frame was to lift the new box up high enough I won't have interference when I'm towing with the pintle hitch.


The extra tab on the lower support will be the lower support for a single jerry can.

Test fit:


Mounted box:


I ended up sandwiching the corner to make sure it wouldn't deflect, even it somebody decides to stand on top (which I'm sure is inevitable):


Lastly, i added a bracket on the side for a jerry can, drilled to take a padlock so I won't loose any more cans. I also ran wire through the box for the LED license plate light.



Overall, it came out pretty nice, and only cost me about $160 for the box, light, and fasteners.
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Old 09-26-2011, 11:47 AM   #2
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Re: Reunel baja box upgrade

Is it just the photo, or does the box paint match the van?

Lookin' good!

Mike
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Old 09-26-2011, 12:18 PM   #3
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Re: Reunel baja box upgrade

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Originally Posted by Ford_6L_E350
Is it just the photo, or does the box paint match the van?

Lookin' good!

Mike

Thanks! The box is actually black, but I think it's shiny enough you are probably seeing the gravel reflection, making it look like the metallic grey on the the van.
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Old 09-26-2011, 02:37 PM   #4
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Re: Reunel baja box upgrade

Thanks for the link carringb, nice build out.
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Old 09-28-2011, 07:59 AM   #5
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Re: Reunel baja box upgrade

What is the dust/water sealing of the box like?
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Old 09-28-2011, 10:19 AM   #6
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Re: Reunel baja box upgrade

Quote:
Originally Posted by jage
What is the dust/water sealing of the box like?
I'll try to take a picture later. But essentially it's a flange forms a c-channel, and on the edge is a nice automotive seal. I drove forest service roads last weekend at 60+MPH and there was NO dust in the box when I got to camp.
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Old 04-20-2012, 10:05 PM   #7
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Re: Reunel baja box upgrade

Carringb, how’s that new box working and holding up?
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Old 04-21-2012, 12:10 AM   #8
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Re: Reunel baja box upgrade

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Originally Posted by BIGVANS
Carringb, how’s that new box working and holding up?
Great! Never has leaked a single drop into the box, even with some pretty heavy rains this year, and lots of nights on the mountain. The only issue is the paint on the top of box isn't shiny anymore. If it doesn't clean up with some wax, I may have to paint the whole thing.

One issue I did not realize I would have: Trailer jack clearance. I knew I was adding more length to the setup, but I didn't realize it would cause the issue it did. Now, anytime I tow a trailer with a vertical jack, I have to use an 8" extension. The reunel can handle it though, and it still tows even large trailers just fine using the extension.
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