Ram Promaster Forum banner
Showcase cover image for Nigel: In floor storage

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


Folded floor boxes, ready to fit


Seat Rails tack welded in place with the seat in the rear most position


And in the Forward Position


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.


Test fit of 1" Insulation + 1/2" ply floor vs Floor box vs seat rail height


Seat raised to final height with floor in place


3mm Vinyl plank cutting and gluing


The Finished product

Comments

· Registered
2019 159 EXT HR (3500) in WA
Joined
·
2,350 Posts
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.
 

· Registered
2018 159"
Joined
·
24 Posts
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
 

· Registered
Van #2 2021 EXT
Joined
·
6,718 Posts
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
 

· Registered
2018 159"
Joined
·
24 Posts
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.
 

· Registered
MMXVI - L2H2 in Indiana
Joined
·
6,796 Posts
@Davo
When you cut the holes in the floor did you cut the flange on the channel? (circled in red)
61400
 
Last edited:

· Registered
2018 159"
Joined
·
24 Posts
@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
 

· Registered
Joined
·
555 Posts
That's a very impressive solution. Truly thinking "under the box" or whatever that expression is.
 

· Registered
Joined
·
0 Posts
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.
 

· Registered
Joined
·
2,121 Posts
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.
 

· Registered
2016 Ram Promaster 136
Joined
·
19 Posts
This is one innovative promaster setup, really nice and inspiring \m/
 

· Registered
Joined
·
34 Posts
Any regrets or lessons learned?

I just paid to have some boxes made out of 5250 aluminum:

Big box by door: 24" x 10" x 8" deep
Two smaller boxes, each 18" x 14" x 8" deep

Both are 8" deep and have a 1.5" flange, any feedback? I'm scared!
 

· Registered
2019 159 EXT HR (3500) in WA
Joined
·
2,350 Posts
Don't be afraid . . . just call it "the first revision" if it does not work out well :)

More helpfully, you can mock up the boxes using duct tape and cardboard, once you are happy with them then have the shop make them out of aluminum.
 

· Registered
Joined
·
0 Posts
@Davo
Really neat execution. I have been mulling the possibility of the dodge minivan stow-n-go seat bins retrofitted in this manner. The depth is about 10" +/- but the distance front to rear seems be greater than that available between the frame cross members of the promaster. It would be a super adaptation to have a full cargo space or pop up two seats for a couple of work crew (or kids).
 

Attachments

· Premium Member
Joined
·
9 Posts
  • Very impressed with the idea and execution.
  • Keep thinking outside BOX my friend.
  • Working on some retrofit ideas of my own.
 
Top