need ideas for DIY folding "truck/cargo box/trunk/job box"

newbury · Jan 2, 2014

For the next several years it looks like I will be slowly dragging all my household from just about DC to northeast Mississippi. And then dragging another household from DC to northern New York.

I've been doing it primarily with cardboard boxes etc.

Now I'm wanting to build some foldable boxes out of wood (w/ lots of metal hinges) so I can put lot's of smaller boxes etc. inside. That way I could haul down more stuff with less worry about theft when they are in the back of my dually or on my trailer.

I'd like to keep the weight under 50lbs so I'm thinking 1/2" PT plywood with 2x3 corner bracing. And I want to be able to fold it up so when I haul it back there is less wind resistance. I figure something on the order of 3+' wide, 2+' high and 2' deep.

Any ideas? Plans?

thanks in advance

bigtiller · Jan 2, 2014

My first thought is if it is 3 feet wide, that makes it expensive to make with plywood, too much scrap. Why not make them 2 or 4 feet wide? They will stack easier that way. Another thought is plastic break-down pallets. They do exactly what you are wanting wood boxes to do and they are much lighter.

newbury · Jan 3, 2014

bigtiller said:
My first thought is if it is 3 feet wide, that makes it expensive to make with plywood, too much scrap. Why not make them 2 or 4 feet wide? They will stack easier that way. Another thought is plastic break-down pallets. They do exactly what you are wanting wood boxes to do and they are much lighter.

At 3' wide I can fit 2 across in my truck bed, and I can carry them easy, 2' wide is to small. And I always have a bunch of "scrap plywood". A 4x8 sheet of plywood can be easily cut into four panels 3'x2' for 2 sides, a top and bottom leaving a 2'x4' piece to be cut into two ends.
/edit - rough drawing not to scale

I've had bad luck with bought plastic containers falling apart after a few years. Wooden carrying boxes I built 30 years ago are still holding together.

hawkeye08 · Jan 3, 2014

I don't think they fold, but moving companies have plywood boxes that they use inside moving vans.

bigtiller · Jan 3, 2014

Duh,, what was I thinking? 3'x2' from a sheet of plywood would have enough left over for a lid and no scrap. I just made a box for an apartment size fridg to set on. It was 2'x2' and 18" tall made with 3/4 plywood. I added a 2"x2" to each butt joint for strength. To make them easier to move, how about routing a slot towards the top for a hand-hold? Or rip a 2x4 into 3/8 strips and glue them all the way around the sides.

BHD · Jan 3, 2014

maybe I just do not understand here, but

my guess you have a pick up truck, how about a topper or shell, over the bed, (I know that is not a box, but I would think it would eliminate the need for a box type of thing).

newbury · Jan 3, 2014

BHD said:
maybe I just do not understand here, but

my guess you have a pick up truck, how about a topper or shell, over the bed, (I know that is not a box, but I would think it would eliminate the need for a box type of thing).

In my sig.
But I also have an 18' trailer I would be putting boxes on. I have several of the plastic "cargo" boxes of about that size but they don't nest or fold.