When I was a senior in high school, I recognized a gap in the Toyota aftermarket for off-road, in-bed storage solutions. I really wanted something that was lightweight, weatherproof, modular, and would allow me to securely strap down heavy objects.
Decked made a cool drawer system, but it was heavy at over 200lbs. Too much lost payload for a midsize pickup. BamBeds made a lightweight and modular platform, but it was pricey, it wasn’t secure, and it was made of wood. GoFastCampers briefly made their “Flight Deck” product which seemed to check all the boxes. However, it was out of my price range, used proprietary aluminum extrusions, and, most importantly, discontinued.
Dissatisfied with my options, I came to the conclusion I’d just have to make one myself…
The objectives were as follows:
Make it modular
Use off-the-shelf aluminum extrusion profiles
Keep it under ~80lbs
Be able to support 1000+lbs distributed
Make it all-metal and weatherproof
Keep the prototype under $800 (excl. powdercoat)
This project was one of my earlier attempts at sheet metal models and mated assemblies. I learned a lot during the process, but if I were to remake the deck, I think I’d start the drawings from scratch.
After two iterations of the 1/8” top plate and the 1/4” hold down plates, the deck bolted together and fit the space well. Now, it was just time for some powder coat!
All ready for final assembly and just under the objective weight at 72 pounds. The whole thing design is likely overkill and could be redesigned to be around 45-50 pounds. If I were to do so, I might try 3/16” side plates instead of 1/4”; 1×2” extrusion instead of 1.5×3”; and 10ga deck plate instead of 1/8”.
Finally, to complete the space, I added a laser-cut MOLLE panel on the driver side and custom electrical panel on the passenger side.
Below is a gallery of the final product, including some use images of it in use. I don’t think I’d change anything about the design: it’s modular enough for my use and way more stout than I need. It’s like having a beefy roof rack in the bed of your truck. The near infinite tie-down options have kept whatever I strap down in the bed from flying around off-road. My favorite configuration for camping is the half-length platform, allowing for full standing height in the bed with the camper popped.
