Cargo shelf

After having no organization in the trunk I decided to make a shelf for the cargo area. I had wood flooring pieces that had been sitting around for a few years, and wanted to make something inexpensive.  The drawer cargo carriers for the FJ ran $400+ and I didn't have much to spend.

 I started by placing the wood flooring pieces together and measuring out the trunk width. I decided on making the shelf 2' by 4'.  Once I had the pieces layer out, I cut the smaller pieces to size and then attached them with stainless hinges that I already had.

The next step was to pick out three other pieces that I would use as a brace for holding each plank.  I then used longer screws and drilled two holes for each plank on the braces. Before doing so I made sure to push all the pieces together prior to screwing in.  Once all the pieces were screwed in, the planks were very tight and sturdy.

Next was to bevel one of the edges so that it would fit under the subwoofer.  It didn't take long using an electric planar. I then used a belt sander to smooth out the edges.

I made a test fit in the trunk and everything worked out. I was planning on using some circular rubber feet on the botton edges so that the shelf wouldn't slide all over the place. Then an idea popped into my head. I had some old inner tubes from my bike that I cut to size and glued them on the edges. Not only would this keep the shelf from sliding, but it would also protect the plastic from being damaged.

Then off to Home Depot to pick up some bins that were about 9.5" high. I also picked up some tie down shackles that I screwed into the top of the shelf.  Now I can hold anything I need on top of the shelf.

Using a rachet tie down, I hooked it diagonally to hold the shelf down.

The bins slid perfectly under the shelf and I was surprised to find out that they had more volume than my old bins that seemed to take up more room in the trunk.

The 2' width of the shelf allowed room behind the seat where I could place taller items like the pieces of wood for use with a jack when needed, the axe and the shovel.

So, with all the materials that I had readily available, I only spent $25 for two bins, four tie down shackles and a ratchet tie down.  Not bad considering that those other fancy drawer systems cost an arm and a leg.

TRD CAI intake issue

I decided to clean out my TRD intake filter this past weekend and found something troubling.  I noticed that the rubber couplings for the TRD intake were cracked and melting.  The larger piece connecting the filter box to the pipe had a small hole underneath that I had to temporarily close with some duct tape that I had lying around.

Large coupling that connects airbox to pipe.

Smaller coupling connecting pipe to throttle body.

I just want to say that I have bought other cold-air intakes and never had this problem.  This was the worst I have seen and was wondering why Toyota would sell something that would deteriorate in less than 8 years.  All my other hoses, which have to perform at hotter temperatures than the intake, are fine.

After researching where I could buy replacement parts, I found out that Toyota did not manufacture this intake.  The company that produced it is called aFe.  I contacted them and apparently they have the two couplings. Unfortunately, they were around $60 for both. I looked elsewhere and found some turbo couplings on ebay.  They both came out to be about $20, were three ply silicone tubing that are high temperature and high pressure tolerant.  I was even able to choose the color I wanted.

New vs. old couplings.

Installed.

The new couplings were a 4" to 4" with bump and a 3" to 2.75" reducer. They were a bit hard to place them on each opening, but once I stretched them enough over the holes, they fit nice and tight.  A larger coupling for the throttle body would probably be a better fit. Next time I will buy the 3" to 3" coupling.  The thickness of the new couplings added to the snug fit. The older ones were much thinner since they were one ply.  Once the clamps were in place, the installation was finished.

So if you have this intake, make sure that you check the couplings.  If a piece of this rubber is sucked into the throttle body and into the engine, you will have major issues.  Not only this, but holes in the couplings will also suck in air behind the filter and all the dust and grime will eventually make its way to the throttle body and into the engine.