The rear cab wall. Normally the spare tire sits between this wall and the driver's seat.
We have a different idea for here. The spare tire will be elsewhere.
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This compartment is behind the cab wall, under the bed, and would have
originally been the rear passenger footwell in the Falcon sedan model.
In the Ranchero, this is lost space. We have a plan to reclaim it.
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Our son had an idea to build a waterproof storage box accessible from the
passenger compartment that would fill in that dead space below the bed floor.
The first step was to remove the cab wall to make the area accessible.
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They calculated the maximum usable area and removed only enough of the cab wall
to get access. This is from inside the passenger compartment.
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Before the boxes could be put in, the lip for the bed floor had to be welded in.
Having these access holes cut made that process easier, albeit you have to be
limber to get into this position.
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A cardboard template for the box was made to check fit and panel size.
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The "box" from the bed side. It will fill the area nicely.
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The pattern was laid out on sheet steel and two boxes were cut out.
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Two storage boxes, some assembly required. Our son used the metal brake at
work to bend the edges here to give a crips fold.
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The driver side box completed and set in place. The final assembly will be welded
in place.
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The box from the bed side. The passenger side cannot be welded in until the
frame rail is repaired as it sits over
the frame rail.
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A better view of the box outside the car. This is the top and back.
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Minor adjustments were made. This is the front.
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Once all adjustments had been made, a final trial fit was done.
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The box from the passenger compartment. Now to work on the doors.
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A frame was built to give the door something to close against while also holding
the catch and the hinge. Fortunately, the frame was the same thickness as the
horizontal cross brace on the cab wall.
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The frame was tig welded up. He chose this so that he could practice tig welding.
At least he is wearing a helmet and gloves.
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One finished frame.
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Now to trial fit the frame.
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A piano hinge was used to hold the door to the frame.
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The door is an aluminum panel. The uneven top edge was straightened later.
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The door to the frame. When opened, the door will lie flat on the floorboard,
allowing full access to the contents of the box.
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An overhead view of both boxes in place. The driver side has been welded in at this point. The
passenger one will be welded in soon.
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The latch is a factory styled glove box catch from a '67 Mustang. We plan to add a
compartment light and a catch chain as well.
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And the small push button opener.
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From the bed, both boxes welded into place. The passenger
side was modified to hold the battery, since it will no
longer fit in the engine bay. The extra weld on the back
of the box is for the battery hold down.
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