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General Information

Name
Nigel
Year
2018
Make
RAM ProMaster
Model
159"
Color
White
Hello All,
I thought I'd put some pictures up showing how we added some in floor storage to our 159" ProMaster.
The extra storage was something we felt would be handy to have and the prospect of utilizing free space under the vehicle enticed us to give it a go. I acknowledge that this might not be everyone's cup of tea but, it is something a bit different and shows another solution to the ever pressing storage issue.
Pros:
Having a place to store shoes, tools, tents etc has been really nice
Cons:
I wont lie, it was bit tricky to get just right. By spending more time thinking than doing, it came out exactly how we wanted, just right.


Test fit of Rear seat and rails with proposed floor box locations
1 Seat and rails test fit.jpg

Folded floor boxes, ready to fit
2 folded boxes.jpg

Seat Rails tack welded in place with the seat in the rear most position
3 Rails tacked in place Seat Rear.jpg

And in the Forward Position
5 Rails Tacked in place Seat Forwad.jpg

No turning back.... holes are cut! I imagine this will create the most discussion. My thoughts were that the floor is just there to stop your stuff falling on the road, this was based on the fact that the chassis is continuous (not monocoquoe) and that the Cutaway variant/model has no floor and can be driven around without disintegrating. I did make sure to not cut into any part of the structural chassis/cross members.
6 Floor holes cut.jpg 7 Floor Boxes Installed.jpg 8 Installed depth.jpg

Test fit of 1" Insulation + 1/2" ply floor vs Floor box vs seat rail height
9 Floor vs box fit.jpg 10 Ready For Finished Floor.jpg

Seat raised to final height with floor in place
11 Seat lifted to final height.jpg

3mm Vinyl plank cutting and gluing
12 Plank Cutting .jpg 13 Planks Layed out.jpg 14 Ready for planks.jpg 15 Mid glue.jpg 16 Finished Floor.jpg 17 Step Edge.jpg

The Finished product
18 In use 1.jpg 19 In Use 2.jpg 20 In use 3.jpg

Comments

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Interesting.

Are the corners of the boxes welded?

How are the boxes fastened to the floor? Welded?

How are they sealed?

How are they finished? Galvanized?

Thanks for the great photos.
 

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Hi Baxsie,
The corners of the boxes are welded, just not in the photo attached. The sheetmetal place I used to cut and fold the boxes wanted an arm and a leg to weld them up so I welded them myself.
The boxes are nyloc nut and bolted to the van floor and sealed with a polyurethane sealant. I contemplated welding them but went with nut and bolt instead.
The sheet steel itself has a zinc/aluminium coating. It's called something else in North America (I think) but I don't recall what it is exactly. Where I welded and finished the edges, I recoated with a Galv paint before painting the boxes with several coats of Rustoleum paint then covered it with some tar based underbody sealer that was a complete nightmare to work with! They should never leak and I doubt they will rust in a hurry. I am always amazed at how clean they are even though they are under the vehicle. It is really only the front edge of the first box that has any dirt on it, the rest look like new.

Thanks for the interest
All the best.
Dave
 

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Davo

Very Innovative !!

I have not seen that before. How did you come up with that idea/design?

I believe the sheet metal coating name might be “Galvalume“, at least that is what your description sounds like.

I am very impressed with the amount of storage, & your design for the capacity of carrying items with you (seems to be at the very top of capacity from what I have seen on the internet).

Thanks for posting
 

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Davo

Very Innovative !!

I have not seen that before. How did you come up with that idea/design?

I believe the sheet metal coating name might be “Galvalume“, at least that is what your description sounds like.

I am very impressed with the amount of storage, & your design for the capacity of carrying items with you (seems to be at the very top of capacity from what I have seen on the internet).

Thanks for posting
Thanks RV8R,
The idea grew from wanting somewhere convenient to put/store all our shoes, Imelda Marcos would have been envious of the shear quantity of our shoes. I guess that's what happens when you each have separate hiking, climbing, riding and running shoes.

As we built the van for full time living, we wanted/needed as much practical storage as possible. Even after reducing all of our possessions down to the bare minimum, we were surprised at how quickly we filled up all the spaces so we were glad to have put in the time to maximise the space available.

I knew the Front Wheel Drive setup of the Promaster would lend itself to more options for utilising the space under the floor (compared to a rear wheel drive) but we wanted to access that space from the inside, not the outside. The initial plan was to just have one box but after looking underneath the van, we could see three available spots and figured we may as well go for broke!
Getting the boxes to lineup with the floor cutouts and to have the finished height of the floor level with the seat rails took a bit of thought and luck to be honest.

Oh and the word for the sheet steel I was looking for was 'Satin Coat', that's what the sheet metal man called it. Google tells me that we are all talking about the same thing which, is reassuring!

All the best to you.
 

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@Davo
When you cut the holes in the floor did you cut the flange on the channel? (circled in red)
61400
 
Last edited:

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@Davo
When you cut the holes in the floor did you cut the flange on the channel? (circled in red)
View attachment 61400
Hi Phil,
Sorry for the delay in reply, I don't seem to be getting notified of comments for some reason.
In answer to your question:
I did not cut the flange on the channel. In my opinion, the flange on the channel is part of the structural member and should be left alone. The boxes sit inboard of the flange by 1 to 2mm ( about .04").

All the best,

Dave
 

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Do you happen to have the dimensions for your boxes? I've had the same idea but I would be using to house batteries. My ram truck has similar boxes at the foot of the rear seats.
 

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Very nice through the floor boxes.

I have seen a similar concept by an upfit group for sprinters, but I didn't like that the installation required cutting a frame member.

Your solution is much better.
 
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