I have a '99 Chevy Tahoe, and those are the measurements I'll give. This concept should be easily adaptable to any SUV, maybe a station wagon, possibly even a pickup truck but the platform would have to be much longer and well-secured.
Step 1: Supplies
- 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
- 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)