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Custom rear cargo spacer for camping, hidden cargo area, etc.

Discussion in 'Gen 4 Prius Main Forum' started by PriusOffroad, Apr 11, 2020.

  1. PriusOffroad

    PriusOffroad Active Member

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    Well I figured I would make the most of the quarantine and start crossing off some projects on the new Prius. I love my gen 4 but I can't help but miss some of the old features from the earlier generations that made me fall in love. One of the biggest disappointments I received with my new Prius was when I lifted up the rear cargo deck hoping to see ample amounts of hidden storage space and was instead greeted by several cubic feet of styrofoam and two measly compartments fit for a textbook or two at best. This was shortly followed by noticing that the cargo area and rear lip is no longer flush for easy loading and unloading. Continuing forward on the car I was nearly equally disappointed when I folded the seats down and found out that the seats no longer fold perfectly flat with the cargo area. Considering I sleep in my car a solid 30-45 nights a year on camping trips and road trips this was a big upset. The fact that it was only off by just shy of 2” further added salt to the wound.

    After a few renditions back at the drawing board and several failed attempts I finally came up with something I'm happy with. I’m sure I’ll tweak things a little once I've used it more but it’s a good foundation. Later down the line I plan on making vertical divider inserts to separate the left, right, and rear cubbies from one another. This will allow me to carry things in their own separate compartment without having to worry about them rolling around or interfering with the electronics.

    Pros:
    Flat surface for carrying cargo, sleeping, etc.
    Flush entry for easy loading/unloading of cargo.
    Increased sub cargo area.
    Return of the side cubbies!
    Reduced weight vs stock.
    Retains factory cargo tie down hooks.
    Can be used with or without exiting styrofoam/plastic inserts.
    Easily put back to stock when selling.

    Cons:
    Side cubbie areas are slightly angled down compared to the rest of the surface.
    Carpeted board has minor amount of flex between bracing when excessive weight is applied. I was able to sit, stand, and lay on it without it breaking but the wood definitely flexes. Might end up cutting out a piece of ¼” plywood for additional support beneath the carpeted area.
    Possible slight increase in rear noise without styrofoam.

    This should work for all 4th gen non PIP Prius, but was designed around the AWDe model.
    It’s made from ⅛” wall 1” angle iron on the border and horizontal cross brace and 1” .¼” flat stock on the vertical bracing. I figure i'll throw a few coats of satin black enamel on it once I venture out to the store. If anyone would like to follow suit and there’s enough interest from other members on here I could make a batch and offer them for sale. If I can get 10 requests I should be able to get a little discount on material and streamline the process where it should only take 2-3 hours per rack. I figure $125 +shipping which should be around $25 anywhere in the continental US. Let me know your thoughts!
     

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  2. lech auto air conditionin

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    I did the same but used 5/8” plywood. No carpet because I use it for heavy duty equipment, tools and supplies. Daily load of 800+ lbs on rear deck.
     
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  3. PriusOffroad

    PriusOffroad Active Member

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    That’s awesome! Any pics of your setup? Did you do an suspension upgrades to handle that weight regularly?
     
  4. krmcg

    krmcg Lowered Blizzard Pearl Beauty

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    great job!
     
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  5. Minima Domum

    Minima Domum Member

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    Awesome work!

    I'm doing this over the next few days too, just finishing off my towbar install and then the interior starts, I really like the idea of using the luggage hook bolts to hold it in.
     
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  6. Mambo Dave

    Mambo Dave Active Member

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    Gosh darn is that cool.

    I was thinking of something similar - something to hold up the rear mat without using the foam at all to create space.

    --------

    That stated, has anyone measured the temperature extremes under the rear seat? I'm wondering if I could use just a little of that area - without using enough to block airflow for battery cooling - for some storage?
     
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  7. lech auto air conditionin

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    Use as much as you want just create a little ducting larger than the diameter of the opening of the fan outside of your box area and you’ll be OK
     
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  8. Mambo Dave

    Mambo Dave Active Member

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    Have you measured the temperatures in that space? Some things may be temperature sensitive to a degree.
     
  9. lech auto air conditionin

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    It’s pulling air through the fan from the cabin department it’s the same temperature as your passenger area unless you are making it absolutely air tight so no air can get in there you don’t have to worry. On most build people are not making an airtight box like a sealed shoebox. It will pull air forward to the path of least resistance as long as it has a pass for fresh air from your cabin department you don’t have to worry. It’s one of those things since this is all I do for a living what temperatures and thermal management it’s so obvious I don’t even have to break out my temperature probes
     
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  10. lech auto air conditionin

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    30056C07-106E-42CE-826E-787C84086740.png DC5590CE-26EF-4476-8F72-3BD9563F8796.jpeg 12BC7CA1-0354-462A-BAE4-8A72777BC87A.jpeg And since my last post I drove from Mill Valley to my house in San Francisco after posting I took out my Fieldpiece temperature probes put one under my seat while I was driving and put the other temperature probe at the screen at the fan inlet to the battery so you can see the difference in temperature from passenger compartment to fan inlet.

    The return air dry bulb is the passenger compartment temperature 57.6°
    The supply air dry bulb is the temperature sensor right at the fan inlet 61°

    When it comes to data logging measuring and controlling temperature that’s what I do for a living. Whether it’s radiant heat, convection heat or conduction heat. Manipulating the path of heat whether to impede or increase is what I do from morning to night every day for the past 30+ years.
     
  11. lech auto air conditionin

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    This is why the guys who live in hot desert areas but are trying to get good gas mileage by not using their air conditioning and keeping their interior temperatures of their car at 80, 90 or 100° and just living with the heat The temperature exponentially increases as the temperatures get hotter. The HV battery does not like that.
    When I drive from San Francisco to Las Vegas in the summer time with my air conditioning on full blast from the start of my travel until I’m in the desert at 110° the inside of my cabin compartment is a nice cool 68°. But of course I take care of my air-conditioning system and service it every 2 to 3 years. From the day I purchased this Prius brand new and it was driven off the showroom floor the air conditioning button was turned on and never turned off from morning tonight 365 in the rain at night time in the fog or in the blazing sun I just adjust temperature and fan speed to comfort but always leave on the air-conditioning.
     
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  12. Mambo Dave

    Mambo Dave Active Member

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    So that battery and the steel against it does not heat up at all beyond the ambient air temperature?

    Seems odd as I'd imagine that item heating up beyond the normal air temp is why it is vented through there.
     
  13. lech auto air conditionin

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    marginal under normal driving Under hard acceleration stop and go or long mountain passes decelerating using regeneration will make more heat but as long as you keep the cabin temperature cool you’ll have no problem. Heat comes from deep discharging in high rates of regeneration or internal battery cell problem with a couple cell getting hot from resistance degrading.

    Keeps coming back to the same old situation keep cabin temperature cool unrestricted fan clean fan blades equals cool operation.
    Lack of proper operating air-conditioning or a customer who decides to get better gas mileage and turn off air conditioning and run cabin temperature hot or lack of maintenance cleaning the blower fan blades or dirty passenger compartment or dogs with shedding hair then that’s driver operator error.
     
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  14. Mambo Dave

    Mambo Dave Active Member

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    That is so excellent - thank you for the data!
     
  15. Mambo Dave

    Mambo Dave Active Member

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    I'm in south Florida - I should probably follow your lead and have mine serviced once every three years. We do, thankfully, get a few weeks during winter where we may not need AC in the early mornings.
     
  16. Frogerelli

    Frogerelli Junior Member

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  17. Frogerelli

    Frogerelli Junior Member

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    PriusOffroad, You did a great job. I would love one for $125 + 25 shipping. Sign me up!
     
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  18. PriusOffroad

    PriusOffroad Active Member

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    Thank you! So far i'm really happy with it. Still haven't gotten around to making dividers for it or adding plywood beneath it, but so far so good! Nice to finally have a flush space and storage beneath it. I'll add you to the list for orders!
     
  19. Purplesquirrel44

    Purplesquirrel44 New Member

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    I would be interested in purchasing one too if it would fit my 2018 Toyota Prius (trim level One).

    Just bought my car a few months ago and only now realized the significant drop that would hinder camping.
     
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