I use my Defender mainly for long distance expedition driving.  Even with a roof tent we do some pretty decent trails, but this is not a rock crawler.

The company I work for makes custom stainless and aluminum products for the foodservice industry - things like tables, sinks, and storage racks that go into restaurants and grocery stores.  We don't do heavy gauge stuff (like bumpers), but can do some pretty nice work on lighter gauge products.

This page documents some of my initial efforts:

So what to build next?...

This is what my company normally makes, and is the basis for the custom vehicle storage racks.

All aluminum = light weight, easy to clean, durable, and no rust. The extrusions are the same as used by grocery stores to store heavy meats, canned goods, etc.

Custom Defender rear storage rack.

See how my two footlockers fit neatly underneath? I can lash down lots of stuff to the top of the rack, and still be able to pull my food locker or spares/repairs locker out without any hassle. With room for that spare axle on the side!

Custom mid-storage rack for Defender. Rear legs are offset and shorter to accomodate tire well and floor height changes.

Note the perfect position of the Engel - easy to pull out, as far forward as possible without interfering with the passenger seat, and easily reachable from either front seat. (I can reach back and grab a soda out of it from the drivers seat, without having to undo my seatbelt)

Custom mid-storage rack for Defender. Rear legs are offset and shorter to accomodate tire well and floor height changes.

View of custom storage racks from drivers seat.

Note the easy access of the fire extinguisher and the Engel from both front seats.

Custom stainless steel jerry can holders on an aluminum deck.

I saw a similar rack on another vehicle, but it was painted mild steel, and I wanted one in stainless!

Custom mid-storage rack for Defender. Rear legs are offset and shorter to accomodate tire well and floor height changes.

Engel removed to show slide rack mounting. The CO2 bottle is attached in 4 places to the bottom rack, and in two places to the rear rack - nice and secure, it's not going anywhere!

You can also see my little inverter for keeping my FRS radios charged, etc.

Custom mid-storage rack for Defender. Rear legs are offset and shorter to accomodate tire well and floor height changes.

Engel removed to show slide rack mounting. The CO2 tank tucks in perfectly, and I don't have to remove it from the vehicle to use it.

Custom mid-storage rack for Defender. Closeup to show structure and weld quality.

Notice the complete welds, this is very strong stuff - tested in both Death Valley and Moab.

Custom Defender rear storage rack.

The space between the slats is perfect for lashing down things on top of the rack. I've also drilled some holes in the side pieces for bungie cords.

Custom Defender rear storage rack.

Out of focus, close up to show fab structure and one of eight body attachment points. This rack has six legs like the one shown. Each corner leg has a single tab bolt down, and the two middle lengs have double tabs (two bolts). It's not going anywhere!

Custom mid-storage rack for Defender.