Extruded aluminium advice for interior buildout.

[Blue Sky]

I've decided I am going to pull the 40 in the 60/40 split rear seats. I plan on building a low profile base made of extruded aluminium so I can run a cooler from the driver rear seat location. My main question is 2020 sufficient or should I go to 4040?

The second question is what is the best method or fastener to use for joining 90 degree angles?

I thought it was going to be pretty easy to get this project going but I have come to find the extruded aluminium space offers a impressive list of ways to build a box.

Any insight is much appreciated.

 

[EOD Guy]

so this is what I came up with to secure my power bank.

EcoFlo power bank platform:
I use my LC for other things besides overlanding........ I wanted a lightweight, easily removed and secure platform to strap the pwr bank to. I didn't want to remove the rear seats etc....... so with the dvr's-rear seat folded forward, I took advantage of the OEM seat catch anchors.

I used 1" 20/20 extruded alum. I cut off about 1" and made a centering/drilling jig, line up the jig with the center hole vertical and the side of the jig lined up with the end of a rail and you can accurately drill a 1/4" through hole that will line up with the rail. The rails are tapped with a 1/4x20 hand tap. I used some low profile 1/4" hex head screws from Amazon. If you look closely you will see, there are three levels........ a base square, two risers/spacers and the top frame. This was done to bypass the obstructions/contours of the floor.

Frame with the top(s) off. The 8 silver magnets (JB weld secures them) that secure the rear portion of the top are visible on the R/H side of the pic.

Rear portion of the top installed (held in place by 8 super strong magnets)

Nylon lashing straps lashing the frame to the seat anchors.

 

[wpage]

Like where this is going. Storage is a problem on the TLC...
so we do what we can. Of course EOD thinks out of the box and innovates his own work outs !

 

[Mopper]

If you have access to a mill to get truly square ends and plunge-cut a 3/4"ish hole through irregular surfaces, Item uses one of the best/strongest corners I've used personally. The Item design has the advantage of staying completely inside the profile of the structural aluminum. Think most of their stuff is compatible with 80/20 (edit: maybe?)

After that, a 2" aluminum beam doesn't flex much over a few feet... how much load? It could be that 20/20 is heavy too?

 

[EOD Guy]

I made my EcoFlow fridge slider out of some 80/20 and bolted some locking heavy duty RV basement sliders for a easily removed slider. Unfortunately, the pictures have been lost in the sauce and I'll have to redocument the build. I actually purchased the Black ones vs the clear ones.

https://www.amazon.com/dp/B001F0G648?tag=landcruiserforum-20

Amazon.com