Modifying the recessed floor in the boot

In a constant strive to increase the cargo space in a Jimny, I got an idea to increase the volume of the recessed floor in the boot (the hole where the vehicle jack, safety triangle etc. are stored).

If I am correct, there is at least 8 cm of distance between the bottom of the boot floor and the exhaust muffler under it.

So the idea is to cut out the recessed floor section from the boot floor, and then design and make a new deeper (and possibly wider) boot floor and weld it onto the vehicle's body.

The end result should be a significantly deeper and possibly wider recessed floor in the boot, which could actually have some useful storage space.

The only additional things to take care of is to put some heat-resistant and heat-insulating material on the bottom of the new floor, in order to protect it from the heat from the exhaust muffler. And also to figure out a new rubber hanger for the exhaust muffler.


Is there any sense in this idea? Has anyone done this?

Why not? You can make it as wide as the boot floor is, and deeper by cca.5cm. That's a lot of volume for such a small boot and it will be usefull.

The muffler hangs off the chassis not the body so no worries there.
It would be worth looking into.

On my car i have to take the muffler out the back opening behind the bumper, and not down to service it because of the trailer hitch. Beware not to close this opening if you need to change the muffler that way..

edit: Increasing the space in the recess would be even more useful if you had a body lift. You could increase the volume at least as much as the body was lifted.

So it's definitely feasible.

You are correct about the muffler hanger going from the chassis. It might still interfere, if the new boot floor is significantly wider. But that can be sorted out somehow.

It's just a matter whether this modification is financially worthwhile, but that is everybody's personal calculation.

So has anybody done (or plans to do) anything similar to this idea?


I agree that a body lift would certainly be very useful in this situation, as long as there are no plans to ever remove the lift.
I suppose that a suspension lift (spacer lift) or installing longer suspension would also provide the same additional space as the body lift of the same height?

Suspension lift will not make anymore space
Body lift will gain space between chassis and boot floor
also give more space above rear silencer as it hangs off chassis


Jack