Sportsmobile/Photomobile Modification

For various reasons (weather, holidays, family matters, personal matters, etc.), I have put off travel (for outdoor photography) for much too long.  Consequently, I have no new photography or journey about which I can blog.  I have plans to remedy this soon.  In the meantime, I have made a few improvements to my Sportsmobile.

As readers know, I acquired a Sportsmobile last year to get to places and provide a place to stay, while on photography expeditions.  Previously, I had to stay in motels, requiring getting up in the very early hours of the morning to drive, then hike to the desired photography site for early morning photo shoots.  If out late in the evening and tired, having to drive back in the dark, trying to stay alert and avoid road hazards, like deer in the roadway.  After a few days of such activity exhaustion is inevitable.

To stay out in a wilderness area for a few days might require extra fuel, so I acquired three two gallon Rotopax diesel fuel containers and mounted them on top of the rear storage box.  These containers are designed to be stacked, either horizontally or vertically.

Rotopax makes various sizes for gasoline, but for some reason they only make the diesel containers in a two gallon size.  These can be mounted onto a vehicle in various ways.  In my case, the top of the rear bumper mounted storage box seemed like the most logical place to put these.  The rack on top of the storage box was just barely wide enough to squeeze in the first container on the bottom of the stack. In fact, I had to slightly tilt the first container at just the right angle and force it into the confines of the rack railing.  While I thought this was ok, I later realized that getting that container out took more effort than I liked, even with an empty container.  I’m sure with a full fuel container, this might prove to be a more difficult and unpleasant task..

To stack the Rotopax containers, there are extensions that go between the containers.

One extension per container is required.  Each extension screws into the base or the extension below it and secures the container below it.  There is also a locking extension accessory.

The Rotopax locking accessory will only secure one container, as putting it on the top of a stack, still allows the entire stack to be rotated, unscrewing the extensions below the locking extension.  I solved this problem by installing an angle bracket onto the storage box such that the upright portion of the angle fits through one of the cutouts in the tank.  This prevents the tank from being rotated.  I covered the angle with a foam materiel held in place by electrical tape to prevent chafing of the fuel container by the bare steel angle.

The reviews of the Rotopax lock noted that it was prone to rust with prolonged exposure to moisture.  The Rotopax manufacturer suggested covering the lock to prevent mud and water from getting into the lock and even only using the lock, when security was required and using a lubricant on a regular basis.  So one could travel with the unlocked stack, then put the lock in position when away from the vehicle.  This seemed a bit too awkward to me, so my first thought was to just put a small tarp over the stack; but a tarp would not keep out dust, which could still accumulate on the fuel containers, maybe resulting in dirt getting into the vehicle fuel tank, when transferring fuel from the container.  Dust getting into the lock might also be a problem and a tarp would just not look cool.  Maybe having a bit too much of “Tim The Tool Man Taylor” in my psyche, I decided to build a box around the unit and remove the rack on top of the storage box, which was already an issue with fitting the bottom container and getting it out of the rack.

But what materiel to use for the cover?  Wood is easy for me to work with, but it would have issues with weathering.  I also though that additional security could be added, if a more robust materiel was used.  So I looked into aluminum, some of which I could acquire from local big box hardware stores, which had the framing materiel readily available, but solid sheets, were more problematic.  Upon further research, I discovered a number of local and online metal suppliers that would even cut pieces to order.  One of these suppliers even had a facility not too far away, where I could order on line and pick up there or have it delivered.  Their price was also about a third of that at the local hardware stores.  So even with paying for shipping, rather than driving 30-45 minutes each way to pick up items, I could save money by ordering online, at least with a substantial order.

After designing the cover, deciding upon the materiel and thickness, I ordered the solid sheets cut to order and lengths of angle, which I could easily cut myself, for the box frame.  The aluminum parts arrive a couple of days after ordering and I set in to working on the cover.

I made a few minor modifications to the initial design, as I went along, as I discovered that I had not thought through the details for some aspects as much as I should have.  So I ended up with a couple of items that I did not use and had to acquire one additional item from the local hardware store, resulting in a bit more cost than had I gotten the proper materiel with the original order.

In the initial installation with the rack in place, I had centered the Rotopax base on the top of the storage box.  In hindsight, had I had in mind this installation without the rack on the box and a cover box, moving the base towards one end of the box, would have left more room inside the box on one end for other storage, like funnels and a self venting filler tube.  (The filler tubes that are inside the Rotopax containers are not self venting to meet certain (California) environmental regulations.  The non-venting spouts make getting fuel out of the containers very slow.  Reviewers complained about this feature and there are self venting spouts one can buy to replace the Rotopax spouts.  I have one of those spouts now.  The containers have to be manually vented anytime the pressure (altitude) or temperature changes significantly, so the emissions regulations, have a limited effect, anyway).

I could still modify the position of the mount and angle; but at this time, I’m leaving well enough alone.  After final assembly, I noted that I can put quart size bottles of oil and/or fuel emergency additives, if desired, at each end of the containers and these fit snugly between the containers and the base angle frame.

The anti-rotation angle, seen in the above photo, could have been left out, since the covering box will be locked; but the cover’s security is not great, so in the event that some determined thief manages to remove the cover, that thief will still have to devote a significant effort into removing the containers with the angle and Rotopax lock in place.

I used stainless steel bolts, screws and locking nuts to assemble the items, so one cannot back out the fasteners without access to the inside.  I did not try to make the box completely water proof, since that is not really necessary.  My initial idea was to thoroughly seal the cover at the seams and around the bolt holes; but as I began the final assembly, I realized that due to the simultaneous fitting together of multiple parts and layers, sealing with any type of sealant would get really messy and my favorite silicon sealant might start to set up before I could tighten all the bolts and screws.  A non-hardening butyl caulk would have worked, but that can be a sticky mess.  I think there might also be sealing tapes that would work or o-rings or rubber washers, but the tape was not readily available and my design did not allow for the thickness of o-rings or rubber washers, which would deteriorate over time, anyway.

Any water that gets in should drain off of the top of the storage box (which I have made sure is sealed) onto which it is attached anyway.  If I find that I want to seal the cover, I can do so later, just by sealing each seam inside the cover.  My fear with this method, is that moisture will be trapped in some places and might result in other problems. I can seal from the outside, but this can be messy and I might ruin the esthetic appearance of the cover, so I will wait to see whether sealing is really necessary or not.

My original plan was to paint the entire box black to match the existing storage box; but when I removed the plastic protective sheet from the aluminum panels, prior to final assembly, I really liked the way it looked.  So I just put on multiple coats of automobile wax, which I hope keeps the finish looking good.  I painted the framing parts black and I think the final product looks good as it is.

I had also planned to give up the original top rack on the storage box, which had to be removed, as previously mentioned for this design.  Then I realized that I might be able to put the rack onto the top of the cover box.  It turned out to be a tight fit, but I was able to make this work and I now have use of the original rack.

This modification obviously reduces the already limited visibility out of the rear window, but I do have a back up camera and really good side view mirrors and cameras, so I do not think this will be a real handicap.

To keep the box in place, I used marine grade, stainless steel, adjustable latches on each end, with padlocks to keep the latches from possibly coming undone with vibration.  The padlocks and latches only provide minimal security, but I’m not overly concerned about that and it is much better than a tarp.

I thought that I might need to add some cushioning materiel where the bottom edge of the cover sits on top of the storage box to prevent chaffing, but the fit is rather tight and can be made even tighter via the adjustable latches, so I do not think this will be a problem.  I will monitor this area and take necessary steps to prevent metal to metal wear, if necessary.

While I can remove the cover and install it while standing on the ground and put the containers in place from ground level, locking and unlocking the Rotopax from ground level is not possible for me.  I can stand on the bumper to do this, but each of these tasks is much easier, if one has a small step stool or ladder upon which to stand.  I looked online for suitable items to use, but I could not find exactly what I wanted and reviews of most lightweight, compact such items were discouraging.  After thinking about this, I realized that the cover box is exactly the right height and it is strong enough for me to stand upon.  But I do not want to stand directly on the top, scratching the finish, and the rack could be a tripping hazard.  I realized that I had plenty of left over suitable lumber from previous home projects for making a standing platform to go over the rack and I have left over aluminum angle that can be used along the edges of the wood to keep the platform in place, when it is in use.  I can store the platform away, if I need to use the rack area for storage or maybe even fit small items into the space below the platform.

I made the rack fit so snugly inside the upper rack rails that it has to be forced into place and I think the fit is tight enough that the platform will not vibrate loose; but just for insurance, I used 1/2 inch pipe clamps over the center vertical rail rod.  The rod is 3/8 inch, so I placed plastic tubing over it to make the clamp fit tightly.  The clamp is fastened with stainless steel wing bolts and self locking nuts.

While I’m at it, I might as well throw in a couple of other handy items that I added.  To clean the front windshield requires a long handle cleaner and squeegee.  Most ordinary fuel stations do not have a long handle windshield cleaner.  After my first road trip in this, I found a long extendable window cleaner and squeegee.  I made a couple of modifications to the extension handle to allow it to be mounted behind the spare tire carrier and allowing for a quick change of window cleaner sponge and squeegee.  I stow the window cleaner and squeegee in a storage compartment within the driver’s side door.  Upon using this for the first time at a fueling station, I noted that the window cleaning sponge is too wide to easily fit into the typically available water box at filling stations.  So I knew I needed to change out those items.

Recently, I found an extendable automobile windshield cleaner that is suitable for use, even though it is not long enough to reach the very top of my windshield.  I thought I could just unscrew the combination windshield cleaner and squeegee and screw it onto the longer handle, but the threads are different!  So I will live with the shorter extension handle, which I mounted behind the storage box.

To hold the handles in place I use 3/8 inch diameter hitch pins through the hitch pin tang on the storage box and/or the tire carrier and support the other end with curtain rod supports.  I found the curtain rod supports in my surplus items in my garage and they are perfect for this purpose.  I could have used the hitch pins that serve to lock the storage box and spare tire carrier in place, when these are swung out; but I figured I will eventually lose one of these, so now I just leave the original hitch pins in their storage holes in the bumper.

Since I will be traveling to cold climates, I also thought it best to acquire an ice scraper.  I found a combination snow brush and ice scraper, which is suitable for a car, but much too short to use on my vehicle.  So I modified that and the longer extension handle, so that I can put either the ice scraper (which I found that I could remove from the snow brush handle) or the snow brush onto the original longer handle.

I also acquired more self rescue items:  Maxtrak boards for sand, mud, snow traction (in case of being stuck), tow strap and shackle, tow hitch receiver with shackle, jack base and wheel chock.  I will be most happy not to ever have to use these, but it is good to have these along, just in case they are ever needed.

Maybe on my next trip into the wilderness, I might get some use from this most recent modification and have something more interesting to write about with photos to share.  I do have one week of a two week trip fairly firmly planned with the second week still uncertain.  The last week’s destination(s) will depend upon the weather.

Stay warm, healthy and safe,

Ken