Cut out a piece of 1/2" or 5/8" plywood - 27 7/8" long
by 6 1/4" wide.
The bottom can be shaped as I did or however you choose. Draw a line
across the plywood 3 3/8" down from the top. Holes will be
centered on this line.
Measuring from right side to left, mark on this line at:
2 1/4", 7 1/4", 12 1/4", 16 3/4", 21 1/2" and
26 1/4". This will be the center for each tube. Also,
pre-drill 3/16" holes on each side and top for mounting brackets.
I used three on the top. I think one in the very center would be
enough.
Use 6 joints of 1 1/4" thin wall PVC water pipe (comes in 12 ft.
lengths).
Mine are cut to 78". The one shown in the photos is in a 21
XD, if you have a 20 XD, the pipes will need to be cut a little
shorter. Pipes need to be cut long enough to lay way up in the
nose. This gives you enough length for most any rod and lets the
pipes lay straight, with no sagging down in the upper end of the
box. The pipe fit into the holes needs to be as tight a fit as
possible.
Once you have them in the plywood, flush on the front side, set it
upright, with the front side down on a flat surface and apply
construction adhesive around each pipe, gluing them to the plywood on
the backside. Use all the adhesive you want, it will never be
seen. Let this dry for 48 hours.
Next, cut a piece of carpet 30" by 8". Lay it face
down on a flat surface and apply carpet adhesive, set the plywood/tubes
on it and let dry for 24 hours.
After it's good and dry, neatly cut around the edges and inside of pipe
with a razor knife.
Now it's ready to install.
You must determine how far back in the box you want it. Mine
is 7 1/2" back from the top lip of the box. This lets me
store both pistol grip and longer handle rods.
What you are looking for is just enough clearance with the rods in the
tubes to close the lid. The kick board on the step will not allow
the rods to move.
Side mounting brackets are 3/4 x 3/4 angle, 3 inches long.
Top bracket is 3/4" wide, 3/16" thick flat metal bent down on
each end, bolted to the cross support brace on the underside of the
floor. The length of this top bracket will be determined by how
far back inside you put the rod holder.
Use 1" x 3/6" stainless bolts with washers and locking nuts.
When installing, remove the front panel and get someone to help guide
the tubes up into the nose. You must clear all wires.
I hope this has not been too confusing. It really works
well.
If I can help, drop me an e-mail.
Jerry Haynes
- KY
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