This project is a modular rear storage system designed to house an oversized spare tire while maximizing the usability of the remaining volume. The layout is driven by the tire envelope and efficiently organizes the leftover space into a full-extension drawer, a large accessible cubby, and additional storage nooks.

The system is engineered for off-road use and designed to withstand sustained vibration and impact loading. Primary structural panels are fabricated from 5052-H32 aluminum sheet, selected for its corrosion resistance and suitability for sheet metal fabrication, while the bottom and rear panels are constructed from HDPE to provide a durable, impact-resistant interface in high-wear areas.

Assembly is achieved using a combination of mechanical fasteners selected for strength, serviceability, and material compatibility, including 5/32″ 18-8 stainless steel blind rivets, 1/4-20 screws and rivnuts, and #10 self-tapping screws for the HDPE components. The design integrates commercial off-the-shelf hardware from McMaster-Carr to simplify sourcing.

This project has given me the opportunity to explore SolidWorks sheet metal tools which are often not utilized on ordinary parts. It also has given me further experience with other engineering skills, such as creating a bill of materials, managing tolerance stack-ups, integrating outsourced hardware, and creating drawings. The most valuable experience from this project, in my opinion, was the hours I spent in the trunk gathering measurements. Despite all of the irregular surfaces, I established functional datums and successfully retrofit new parts.