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DIY: Modding a large Pelican Case. ( Storage & Table )

Discussion in 'Garage / Workshop' started by sytfu510, Dec 24, 2012.

  1. Dec 24, 2012 at 11:23 AM
    #1
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    So many months ago I purchased a large pelican case.

    Same one as this: ( I ended up with 2, bought one for a friend that later changed his mind ) This is the picture of my extra one.

    [​IMG]

    Fits perfectly in the bed of my DCLB. Has wheels and latches with handles. Makes it fairly easy to load even when it's loaded up with off road gear and spare parts.

    However I decided that I wanted to get more use out of it. Thus I wanted to see how I could make improvements to it. :cool:

    So first off I keep a spare front axle in the case whenever I go off road, only issue was it would move around and being heavy it would smash up anything else near it so I have to figure out a solution.

    My solution was to use a quick-fist clamp and bolt it to the side of the case, seal the hole so the case will retain it's seal. And be able to keep the axle from moving around.

    This is what I used to seal it, and in the background you can see the bolts.

    [​IMG]

    The next part is simple, I just measured out where I needed the hole to be and drilled it through. Put sealant on the hole then the bolt & washer through it. Then added a spacer on it and bolted the quick fist on.

    [​IMG]

    With that taken care of I needed to add some loops to hook cords on to keep the stuff in order. Bought some threaded eyelets and did the similar drill and seal as with the clamp:

    [​IMG]

    [​IMG]

    Then I wanted to do something with the top, I thought about how I could add some legs to it to make the top a table. So while wheelin' or camping I can pop the top off and set it up.

    I purchased some 17mm bolts about 4" long with lock washers and nuts. Bought (4) 3ft sticks of square weldable steel that was slightly smaller in inner diameter than the 17mm bolt.

    As I looked at the cover I noticed there were flash marks from when the unit was molded. I drilled them out and used the sealant and bolted the bolts through.

    Flashing Mark:
    [​IMG]

    Hole drilled:
    [​IMG]

    Sealant Added:
    [​IMG]

    Bolt and Nut with Lock washer:
    [​IMG]

    Tightened it down:
    [​IMG]

    Here on the top right you can see the completed bolt:
    [​IMG]

    Then had to drill out the legs for the table. So taking those (4) 3ft square tubing from earlier I had to modify them to accept the 17mm bolt. Using a step bit I stepped it down a few levels until they slid over the bolts.

    [​IMG]

    When I finished I slid the leg over to make sure it fit and added some rubber caps at the end for feet.
    [​IMG]

    Then repeat 3 more times and you have the base going.
    [​IMG]

    I still need to get some flat steel to connect the two legs on each side, so it won't be wobble. But it can support some decent weight as you saw above.

    I will update once I get that done. Then Paint the legs with Bed Liner.

    But overall I'm hoping it will work out well. The legs will be removable and fold inside and can setup quickly.

    ON a side note I picked up some clear plastic locking containers and split the gear.

    -Spare Parts in the bottom ( Ball Joints/Tie Rods/Rad Cap/Thermostat/etc)
    -First Aid/MRE/etc

    [​IMG]

    Thanks for reading! Will update as I make changes.:D
     
  2. Dec 24, 2012 at 11:25 AM
    #2
    OZ-T

    OZ-T All of those moments....will be lost.....in time

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    Awesome

    I was just thinking along these same lines this week

    Is that a 1690 case ?
     
  3. Dec 24, 2012 at 11:26 AM
    #3
    senojeelnodnarb

    senojeelnodnarb Well-Known Member

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    awesome idea. i should have brought on of those back from deployment when i had the chance.
     
  4. Dec 24, 2012 at 11:42 AM
    #4
    av8er2012

    av8er2012 Well-Known Member

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    good idea!
     
  5. Dec 24, 2012 at 11:42 AM
    #5
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    Correct.

    Thanks!
     
  6. Dec 24, 2012 at 11:43 AM
    #6
    OZ-T

    OZ-T All of those moments....will be lost.....in time

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    Awesome , same one I was thinking of getting

    Love it
     
  7. Dec 25, 2012 at 2:04 AM
    #7
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    Thanks! I'll keep this updated as I make changes to fit the needs.

    FYI for anyone interested I do have an extra on for sale. ( The very first pic in the thread )
     
  8. Dec 31, 2012 at 12:20 AM
    #8
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    Update:

    So I had to reinforce the legs to keep it from being too unstable. My solution was to put in a brace across the legs. ( One on each side )

    Flat Steel:

    [​IMG]

    Holes marked and bolts ready:

    [​IMG]

    Held the piece up to the legs and used a level to even it out. Then Marked and drilled the holes in the legs.

    [​IMG]

    Bolted together:

    [​IMG]

    Will update as progress continues. May end up welding it later when I get access to a welder.
     
  9. Jan 4, 2013 at 12:16 PM
    #9
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    Had the legs welded together the bolts didn't work out too well. The Top is still somewhat wobbles but I stand it next to my swing-arm and it's ok.

    [​IMG]
    [​IMG]

    Under the Lid I added a threaded loop:

    [​IMG]

    Now I can hook this Harbor Freight Light underneath so I can see stuff under:

    [​IMG]
     
  10. Jan 4, 2013 at 12:18 PM
    #10
    tinker_troy

    tinker_troy I feel so Devo

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    Good stuff! :thumbsup:
     
  11. Jan 4, 2013 at 12:24 PM
    #11
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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  12. Jun 22, 2015 at 11:08 AM
    #12
    kbraunphoto

    kbraunphoto mountain bike haulin' & off camping

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    Hey @sytfu510 , do you have these photos anymore?
    good ol thread revival, I was looking to do the same type of thing.
     
  13. Jun 22, 2015 at 9:02 PM
    #13
    sytfu510

    sytfu510 [OP] INSTAGRAM: sytfu510

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    I'll look around. Not sure if I saved it.
     
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