Rear window metal replacement rack

[rallypanam]

This idea has been noodling around in my brain for years.. I never open the shades in the rear windows, so why do I even have the windows? Why not utilize the window space for storage?

I started searching for solid doors at junkyards here and there over the last couple years, but the very few I could find (almost all have windows) were beat to ****.

So plan B.. replace the glass with metal, and go from there. I contacted OptOverland as supposedly they make sheet metal replacement windows, but only for the side ones. Apparently, it was up to me.

Brought a glass spare window over to one of my local sheet metal places, and they roughly formed the window out of 1/8 Aluminum. I cleaned it up, drilled holes, and had it powdercoated.

I also added aluminum unistrut in two horizontal bars to carry the load, so the aluminum 'window' is not carrying the load.

I added more holes top and bottom to make sure aluminum sealed, as it's not as stiff as glass. Used extra stock window bolts for these, sourced at a junkyard.

The unistrut is held with 1/4-20 SS bolts.

Then I could add the exterior accessories:

Aluminess 'Expedition Kit' with shovel and axe..

and Power Tank aluminum 2.5 gallon propane bottle holder.

And on the inside, I mounted my Eccotemp hot shower, so (once I plumb it in) I can just open the rear door and have a nice hot shower!

 

[arctictraveller]

Looks great. I took out my replacement plywood window because the A/C unit failed after the second use. Aparently it wasn't rated for offroad use. Interestingly, I had set the wood in silicone seal, and I had a **** of a time getting it out. I bent the pinch weld in several places trying to pry it out, but it finally gave up. After straighting out the metal, and spending over an hour cleaning it up, I replaced the original window VERY carefully and set it in Butyl this time, so when I replace the A/C, the window should come out much easier. The plywood worked ok, but aluminum should be better. Did the sheet metal shop roll in the curve to match the door, or did you form it by bolting it in? I had to cut a series of slots in the wood to get it to bend. Did you make more of these? Great, I'll take one for each side, Thanks.................

 

[RVflyfish]

That's pretty sweet. The van I just bought my girl has a broken Mark III style side window that's a non-standard size. I've searched everywhere trying to find a replacement with no luck. Aluminum sheet like this would be perfect. Nice job.

 

[rallypanam]

Looks great. I took out my replacement plywood window because the A/C unit failed after the second use. Aparently it wasn't rated for offroad use. Interestingly, I had set the wood in silicone seal, and I had a **** of a time getting it out. I bent the pinch weld in several places trying to pry it out, but it finally gave up. After straighting out the metal, and spending over an hour cleaning it up, I replaced the original window VERY carefully and set it in Butyl this time, so when I replace the A/C, the window should come out much easier. The plywood worked ok, but aluminum should be better. Did the sheet metal shop roll in the curve to match the door, or did you form it by bolting it in? I had to cut a series of slots in the wood to get it to bend. Did you make more of these? Great, I'll take one for each side, Thanks.................

Sheet metal shop rolled it to window curve.

I could make more, but it's be a lot cheaper for you to visit a sheet metal shop near you..

 

[1der]

Nice job Robb!!! Great concept and execution

 

[86Scotty]

Looks good Rob. I thought of that a couple times before and had plans to do it to my Vanagon big rear window and mount the spare there. The depth on the inside is pretty helpful too. i chose to just put some 1/4" wood and make a pocket on mine. I think the Transit is a good bit deeper than the E-series though.

Untitled by 86scotty, on Flickr

Untitled by 86scotty, on Flickr

 

[Smoker-SMB]

Well done. I love the ingenuity. I'm planning to get the side panels from Opt Overland. I think they may be doing rear windows now (or soon). When I contacted Dai recently to order, he asked if I needed the rear door panels too. I passed for now since I just purchased a set of pop-out glass for the back doors.

 

[Twoxentrix]

Very inventive - this is the kind of stuff that inspires the rest of us to think out-of-the-box. Like it a lot !
If you had to make an educated guess, would you say your application could hold about 65lbs ? Thinking of possibly mounting 4 of the 2 gal Rotopax RX-2D Diesel Fuel Containers - from the looks of what you already have mounted, 25-30lbs is no issue.

 

[rallypanam]

Very inventive - this is the kind of stuff that inspires the rest of us to think out-of-the-box. Like it a lot !
If you had to make an educated guess, would you say your application could hold about 65lbs ? Thinking of possibly mounting 4 of the 2 gal Rotopax RX-2D Diesel Fuel Containers - from the looks of what you already have mounted, 25-30lbs is no issue.

The only concern I have on weight is the stock ford hinges.. the unistrut will hold plenty. But plenty of people (including SMBs) have been running around for years with the spare mounted to the door, so I figure the door can handle some weight.

I'm considering doing the other side to carry extra water.. Either in a single 5 gallon Scepter can or several smaller rotopax.. I'll mull that over for the next year or two.

 

[Scalf77]

Great Idea, When you staring to take orders?
:b5:

 

[Bbasso]

I dig it!
But I hope you don't encounter the same problem I have with the ecco-temp mounted there...
If it's windy or even breezy the flame gets knocked out and then the cold water comes but then the gas builds and if you don't wait long enough to restart the unit it will basically blow up ( almost harmlessly) I've lost some hair on my arms twice.
Try to build a wind guard.

 

[rallypanam]

I dig it!
But I hope you don't encounter the same problem I have with the ecco-temp mounted there...
If it's windy or even breezy the flame gets knocked out and then the cold water comes but then the gas builds and if you don't wait long enough to restart the unit it will basically blow up ( almost harmlessly) I've lost some hair on my arms twice.
Try to build a wind guard.

Never had that problem.. I've had mine for years and love it!

 

[Bbasso]

Oh, don't get me wrong, I too love it.
Mine is mounted on the 40 door...

 

[shenrie]

that looks really good rob, great idea and nice work!

can you think of any reason why someone couldn't do this same mod with pop-out window hardware and retaining some airflow capabilities?

 

[rallypanam]

that looks really good rob, great idea and nice work!

can you think of any reason why someone couldn't do this same mod with pop-out window hardware and retaining some airflow capabilities?

It would probably lose some weight carrying capacity... but otherwise I don’t see why it wouldn’t work.

 

[BrianW.]

I'd be concerned about hanging any sort of weight off the pop-out window hardware, as it's only basically two attachment points (at the top) that hold the window to the frame (which is attached to the door itself). In this mod the metal plate is very well-bolted to the door with many bolts.

 

[86Scotty]

I second this emotion ^^^

:b5:

 

[Czar308]

Brought a glass spare window over to one of my local sheet metal places, and they roughly formed the window out of 1/8 Aluminum. I cleaned it up, drilled holes, and had it powdercoated.

Nice work on the window. Mind sharing the name of this fabricator/sheet metal shop/powdercoater? There are quite a few of us SF bay area folk on this forum and I'm sure at some point at least one of us will be struck with inspiration and may need such a service. Always nice to have a resource at hand that a member on the forum had a good experince.

 

[rallypanam]

Nice work on the window. Mind sharing the name of this fabricator/sheet metal shop/powdercoater? There are quite a few of us SF bay area folk on this forum and I'm sure at some point at least one of us will be struck with inspiration and may need such a service. Always nice to have a resorce at hand that a member on the forum had a good experince.

For this I used a Chinese owned sheet metal shop in HP. Don't know the name, just know it by site. Down on maybe Gilman? There's another shop I use on Industrial... don't know the name of that one either!

And for powdercoating I use Champion, also in HP. The owner grew up with a good friend of mine, and they do good work pretty cheap and very quick.

 

[oxOneManArmyxo]

Re: Propane Tank Attachment to Sheet Metal Rear Window

Sir..
I'm extremely interested in/
What kind of track you used and..
What attachment method you utilized
In orderTo attach that propane tank to the window. Please! Could you expand on how you accomplished this? I’d be much obliged!
Thank you in advance..
~Mikael