The "bed" of my Tahoe is 48" by 48", so this is sized for my Tahoe. I will include descriptions so that you can alter it for your own vehicle width (side to side, measure at the narrowest part of your cargo area) and depth (back of the seats to the lip of the cargo area--leave enough room to close your doors or tailgate).Parts
- 2 x 3/4" plywood sheet, 48" (width) by 48" (depth) -- I was able to buy one 4' by 8' sheet and cut it in half.
- 4 x 48" (depth) 2.25"x1.5" slotted angle iron
- 2 x sets of "Appliance Rollers"
- 30 x #8 x 5/8" screws -- you may need more or fewer depending on the length of your cargo area
- 10 x washers to fit the #8 screws -- you may need more or fewer
- 10 x 1/2" long bolts, with rounded heads, not hex, each with washer and lock nut -- you may need more or fewer
- 1 2" long bolt; 1/4" or 3/8" diameter
You're probably also going to want some sand paper, possibly some wood finish or paint. If you're going to put this in an area exposed to the elements (like a pickup truck bed) you should certainly paint or finish it.Tools
- Eye protection and gloves, sensible clothing
- Pencil for marking measurements and screw hole locations
- Measuring tape
- Philips head screwdriver
- Socket wrench with socket to fit the lock nuts
- Circular saw, table saw, or other wood saw with a blade to cut plywood
- Drill with 1/2" bit for "stop" hole, 5/64" bit for screw pilot hole, and Phillips screwdriver bit
- Metal cutting saw, hacksaw -- possibly optional
- Angle grinder -- possibly optional, but I strongly recommend it
- A pair of clamps if you're going to be using an angle grinder or if you're going to be making any precise circular saw cuts, or for many other uses.
- Router if you've got access to one (lucky you)