Bed height / side extension from Exceedfab

[Exceed Fabrication]

We started this project around June of last year, but it was put on hold because we couldn't resolve the tailgate seal issue.

Seeing this thread a couple of days ago rekindled my interest,

https://www.jeepgladiatorforum.com/...eight-2-inches-experiment.98302/#post-1590752

so I'm going to document our development process here to see if anyone is interested or can offer some suggestions.

Here are our thoughts on this product:

1. It's essentially a duplicate of the bed edge, raised, so theoretically it should be compatible with all bed accessories—covers, racks, anything.

2. It shouldn't be more expensive or heavier than a bed cap, otherwise it defeats the purpose; it should simply extend the bed to provide more dry storage space.

3. Initially, we considered using an all-steel structure, but it's incredibly heavy. I haven't weighed it, but I think it weighs at least 90 pounds, which is obviously not conducive to the Gladiator's limited payload capacity. Aluminum isn't an ideal load-bearing material, so thinner steel panels with reinforced support columns, or aluminum panels with steel supports, might be the ultimate choice. 4. Its height is about 5.9 inches (if I remember correctly), and it's flush with the bottom edge of the rear glass window to minimize interference with the rearview mirror's view.
5. To make it compatible with existing bed covers, we could add T-slots or external rails, as shown in the rendering.
6. Initially, we considered adding a lower MOLLE extension, but after consulting with some people, they said it wasn't necessary, so we shelved the idea.
7. My concern is that it might extend the moment arm of the rack load on the bed, causing the bed to twist during extreme off-roading. Perhaps adding some bars connected to the inside of the bed to hold it in place would be a good idea. I'd also recommend using this extension instead of a full-height rack; a shorter rack or crossbar would be fine.
8. As I mentioned at the beginning, the biggest challenge with this product is sealing the tailgate. Creating a four-fold cover or a swivel roller cover might solve the problem, but that would obviously make everything more complicated. Alternatively, as shown in the illustration, we could have two small doors, but manufacturing tolerances would also be a problem, so we haven't decided on a solution yet.

So what do you think of this product? Is it an interesting idea? Or is it just a ridiculous piece of crap?

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[smlobx]

Using the last picture would you still be able to roll up or open the tonneau if you have a rtt on it?

 

[Chasm]

I like the slotted corners looking like pillboxes.

 

[Exceed Fabrication]

Using the last picture would you still be able to roll up or open the tonneau if you have a rtt on it?

Yes sir, it can, because if you use the rack in the last picture, the whole frame will be outside the body and will not hinder the tonneau

 

[Exceed Fabrication]

I like the slotted corners looking like pillboxes.

Yes, it's very similar! We want the tailgate to open 270 degrees until it's flush against the sides of the body. Opening it 90 or 180 degrees would leave two metal plates suspended in mid-air, and I don't want them to hit a child's head.

But we're likely to abandon this design because the structure is too complex and the groove would be difficult to waterproof.

 

[Pips_the_JT]

We started this project around June of last year, but it was put on hold because we couldn't resolve the tailgate seal issue.

Seeing this thread a couple of days ago rekindled my interest,

https://www.jeepgladiatorforum.com/...eight-2-inches-experiment.98302/#post-1590752

so I'm going to document our development process here to see if anyone is interested or can offer some suggestions.

Here are our thoughts on this product:

1. It's essentially a duplicate of the bed edge, raised, so theoretically it should be compatible with all bed accessories—covers, racks, anything.

2. It shouldn't be more expensive or heavier than a bed cap, otherwise it defeats the purpose; it should simply extend the bed to provide more dry storage space.

3. Initially, we considered using an all-steel structure, but it's incredibly heavy. I haven't weighed it, but I think it weighs at least 90 pounds, which is obviously not conducive to the Gladiator's limited payload capacity. Aluminum isn't an ideal load-bearing material, so thinner steel panels with reinforced support columns, or aluminum panels with steel supports, might be the ultimate choice. 4. Its height is about 5.9 inches (if I remember correctly), and it's flush with the bottom edge of the rear glass window to minimize interference with the rearview mirror's view.
5. To make it compatible with existing bed covers, we could add T-slots or external rails, as shown in the rendering.
6. Initially, we considered adding a lower MOLLE extension, but after consulting with some people, they said it wasn't necessary, so we shelved the idea.
7. My concern is that it might extend the moment arm of the rack load on the bed, causing the bed to twist during extreme off-roading. Perhaps adding some bars connected to the inside of the bed to hold it in place would be a good idea. I'd also recommend using this extension instead of a full-height rack; a shorter rack or crossbar would be fine.
8. As I mentioned at the beginning, the biggest challenge with this product is sealing the tailgate. Creating a four-fold cover or a swivel roller cover might solve the problem, but that would obviously make everything more complicated. Alternatively, as shown in the illustration, we could have two small doors, but manufacturing tolerances would also be a problem, so we haven't decided on a solution yet.

So what do you think of this product? Is it an interesting idea? Or is it just a ridiculous piece of crap?

for the tailgate, maybe make it an inward swinging "door" like the ones found in walk-in tubs? those seal based on the pressure pushed against them but yours could click into place to make a water tight seal.

 

[TwelveSoldier]

Would be a good spot to put the HiLift jack and small box for ropes and snatches.

 

[Caspien]

Interesting concept. I like the IDEA of it, but its definitely going to need some polish for it to sell.

Love the idea of making the back end the same height as the cab...

Could also consider steel supports, and 'poly' panels. If you go that route, you could even make the panels modular, for easy swap in and swap out for owners of the system.

The biggest issue I can see, is that many people who will opt for something like this, may just retrofit lumber support verticals, and then plywood/MDF for the sides. Coated in a bedliner material, and most people probably wouldn't even know it's wood, at initial glance.

Like the IDEA, not sure about the current execution. Keep it up, though.. love seeing this stuff

 

[loganjeeps]

Love the idea. Like any Jeep product will get more variable opinions than you probably want.

I would throw out there it may not need to be quite that tall. Personally I've found I'm needing only 2-3 more inches in height to get some common sized coolers and storage boxes under my tonneau. Worth noting, the Colorado, Ranger, and Tacoma are all about 3-3.5 inches taller than the Gladiator so that says something about the market.

 

[smlobx]

Love the idea. Like any Jeep product will get more variable opinions than you probably want.

I would throw out there it may not need to be quite that tall. Personally I've found I'm needing only 2-3 more inches in height to get some common sized coolers and storage boxes under my tonneau. Worth noting, the Colorado, Ranger, and Tacoma are all about 3-3.5 inches taller than the Gladiator so that says something about the market.

I think for a lot of guys in the Overlanding World if they could keep the top of their RTT at or below the roof height of the cab it would be a go. Figure 12 inches for the tent and that will cover 99% of uses.

 

[Figmo]

Since you asked....

IM(not so)HO: There is zero chance of developing this product and keeping the cost within your stated goal.

That said, making storage boxes along the length of it will increase cost - but also perceived value. In other words, instead of trying to make it cheaper - make it better. It will cost more money, but also be more worth it.

As for the tailgate, have you considered shifting your thought process from trying to integrate with your side risers somehow - to attaching it to the tailgate itself? A bolt on filler piece on the tailgate?

 

[loganjeeps]

I think for a lot of guys in the Overlanding World if they could keep the top of their RTT at or below the roof height of the cab it would be a go. Figure 12 inches for the tent and that will cover 99% of uses.

probably so but i think OP has the right thinking on the riser height alone by not going higher than the rear window. for every overlander that is willing to block their rear view with a tent there are ten regular folks that don't want their rear view blocked.

 

[Rubianderson]

We started this project around June of last year, but it was put on hold because we couldn't resolve the tailgate seal issue.

Seeing this thread a couple of days ago rekindled my interest,

https://www.jeepgladiatorforum.com/...eight-2-inches-experiment.98302/#post-1590752

so I'm going to document our development process here to see if anyone is interested or can offer some suggestions.

Here are our thoughts on this product:

1. It's essentially a duplicate of the bed edge, raised, so theoretically it should be compatible with all bed accessories—covers, racks, anything.

2. It shouldn't be more expensive or heavier than a bed cap, otherwise it defeats the purpose; it should simply extend the bed to provide more dry storage space.

3. Initially, we considered using an all-steel structure, but it's incredibly heavy. I haven't weighed it, but I think it weighs at least 90 pounds, which is obviously not conducive to the Gladiator's limited payload capacity. Aluminum isn't an ideal load-bearing material, so thinner steel panels with reinforced support columns, or aluminum panels with steel supports, might be the ultimate choice. 4. Its height is about 5.9 inches (if I remember correctly), and it's flush with the bottom edge of the rear glass window to minimize interference with the rearview mirror's view.
5. To make it compatible with existing bed covers, we could add T-slots or external rails, as shown in the rendering.
6. Initially, we considered adding a lower MOLLE extension, but after consulting with some people, they said it wasn't necessary, so we shelved the idea.
7. My concern is that it might extend the moment arm of the rack load on the bed, causing the bed to twist during extreme off-roading. Perhaps adding some bars connected to the inside of the bed to hold it in place would be a good idea. I'd also recommend using this extension instead of a full-height rack; a shorter rack or crossbar would be fine.
8. As I mentioned at the beginning, the biggest challenge with this product is sealing the tailgate. Creating a four-fold cover or a swivel roller cover might solve the problem, but that would obviously make everything more complicated. Alternatively, as shown in the illustration, we could have two small doors, but manufacturing tolerances would also be a problem, so we haven't decided on a solution yet.

So what do you think of this product? Is it an interesting idea? Or is it just a ridiculous piece of crap?

I'd say an interesting idea-worth pursuing

 

[Exceed Fabrication]

for the tailgate, maybe make it an inward swinging "door" like the ones found in walk-in tubs? those seal based on the pressure pushed against them but yours could click into place to make a water tight seal.

We thought about this, and the biggest problem with the inward-swinging door is that it gets blocked when you put cargo in the bed.

 

[Exceed Fabrication]

Interesting concept. I like the IDEA of it, but its definitely going to need some polish for it to sell.

Love the idea of making the back end the same height as the cab...

Could also consider steel supports, and 'poly' panels. If you go that route, you could even make the panels modular, for easy swap in and swap out for owners of the system.

The biggest issue I can see, is that many people who will opt for something like this, may just retrofit lumber support verticals, and then plywood/MDF for the sides. Coated in a bedliner material, and most people probably wouldn't even know it's wood, at initial glance.

Like the IDEA, not sure about the current execution. Keep it up, though.. love seeing this stuff

Thank you for your detailed suggestions!
Polyethylene panels would require us to develop molds, which would incur higher R&D costs, but they clearly offer a significant weight reduction and still get the job done. Furthermore, if I purchased a polyethylene + metal product, I'd feel it was a more well-made product, as it involves multiple factories, which greatly tests the brand's resource integration capabilities.
In short, I will seriously consider your suggestions, and I think polyethylene or aluminum alloy panels are worth the investment. It's like architecture: the load-bearing part is the frame, not the walls. The walls only require basic sealing.

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