Judy's van with the Hitch Haul on the Alacan. It was a life-saver and made the trip possible.

Judy’s van with the Hitch Haul on the Alacan. It was a life-saver and made the trip possible.

After months of nothing but travelogues and photos it’s time to get back to a more normal type of post and deal with some of the nuts and bolts of vandwelling. I’ve been promising some posts about a couple in a van so we’ll start with how we converted Judy’s van so we could both live in it.
She and I had been talking about how much the cost of the trip to Alaska would be and while I have extra money  because of a Workman’s Compensation settlement, Judy is on a very tight budget and has no extra money to spend. In fact, the more we looked at it the less likely it seemed that she could afford the trip (I’ll do a post on the costs of the trip soon, be patient). I suggested we could just take one van instead of both and that would cut the price of gas in half; then she could afford the trip. We both thought that was very impractical because one person in a van is crowded, two people in a van is very difficult and two people and an 80 pound dog is just laughable—it could never happen! So we dropped it.
In this shot we were way back in Idaho on a dirt road but no dust got in the Husky Job Box. Notice we bungeed Judy's chair and my chair to the box. Also notice that the license plate is easily visible above the smaller Actionpacker.

In this shot we were way back in Idaho on a dirt road and the boxes are both covered with dust, but none got in the Husky Job Box. Notice we bungeed Judy’s chair and my chair to the box. Also notice that the license plate is easily visible above the smaller Actionpacker.

As the time drew closer it was just about a certainty she couldn’t go because of the money. I didn’t like that so I told her we had no choice but take just one van, we simply had to find a way to make it work. I’ve been doing this so long, and I’ve talked to so many people that I knew we could figure it out and make it reasonably comfortable for two; after all, necessity is the mother of invention.
This is a friends swing-away box. It's ideal but very expensive.

This is a friends swing-away box. It’s ideal but very expensive.

My first suggestion was we had to get a Hitch Haul for the back receiver. She didn’t want and couldn’t afford one, so I would buy it to use on the trip and it would be mine. I know several people with the swing-away cargo boxes on their van and they are wonderful! They’re large, have good locks and best of all they swing away to open the doors While they would meet our needs extremely well, they are also very expensive! About the cheapest one I found was $750 on Amazon.com. Find it here: StowAway Max Cargo Carrier with Swing-away Frame
That was just too much money for me, so I needed another option
This is another friends box but again, it is very expensive.

This is another friends box but again, it is very expensive.

My friends box open. It's amazing but I just can't justify the cost.

My friends box open. It’s amazing but I just can’t justify the cost.

I decided the only way I could afford it was to buy a standard Hitch Haul cargo carrier and then find a box that would work and mount it on the rack. That meant we could only open the back door about a foot, but that was the way it had to be. Before I could buy the box I had to know the exact dimensions of the carrier so I started searching for one. There was no doubt that I would buy it from Amazon.com because they had a huge selection and with my Prime account I could get it with free 2-day shipping. So I started the search for the one that would work for us. First I had to chose between aluminum and steel. I would have preferred aluminum but I couldn’t find one that met all my needs so I settled on a little extra weight. I had four priorities:

  1. I wanted the largest one I could find so we could put the most things on it.
  2. Sides so cargo could be held in and other things could easily be bungeed to it.
  3. As cheap as possible since I wouldn’t use it often.
  4. Good reviews so it would hold up and be reliable.
This is the one I settled on. At $124 it met all my needs and was a reasonable price.

This is the one I settled on. At $124 it met all my needs and was a reasonable price. It’s 60 x 24 which is as big as they come; has 6 inch sides; had great reviews, and the rise from the receiver  keeps it from dragging. It has worked perfectly! Notice also the ratchet strap to keep it from wobbling .

I searched through Amazon and found one that filled all my requirements. It was 60 x 24 inches which was as big as any I could find and it had 6 inch sides that were perfect to attach bungee cords to. At $124 the price was reasonable and it had outstanding reviews. You can order it from Amazon.com here: Pro Series 60″ x 24″ Hitch Mounted Cargo Carrier
It was time to pull the trigger so I ordered it and two days later it arrived. With it in hand it was time to figure out what I was going to use for a box to mount to it. We had some requirements for whatever box we finally settled on:

  1. The Alcan has a lot of dirt stretches that create a lot of dust and we had to have something that would keep our stuff safe from dust.
  2. There was no question we would be driving through a lot of rain so the box had to be watertight.
  3. Theft is always an issue so I wanted a way to securely lock our stuff away.

The cheapest solution was plastic totes bungeed to the Hitch Haul which would have cost less than $30. The price was right but nothing else was. They wouldn’t be dust and rain proof and they would be extremely easy to steal. I liked the price but there was no way we would use them.

Both the boxes sitting on the rack.

Both the boxes sitting on the rack.

I’ve owned several Rubbermaid products called Actionpackers http://www.amazon.com/Rubbermaid-1172-ActionPacker-Storage-Gallon/dp/B00002N6SQ/ and they would work well. They are a heavy plastic that can be locked and made secure and are also rain and dust proof. I still have two of the 24 gallon ones but didn’t want to take them. Since I bought mine they have come out with a 48 gallon model that would have worked well. I looked all over Flagstaff and couldn’t find either size!! I could order one from Amazon but that would be expensive and I didn’t want to wait. I needed another idea.
Both boxes open. The Job Box has a small lift-out tool box we found very handy.

Both boxes open. The Job Box has a small lift-out tool box we found very handy.

I had gone to every store in town searching for the Actionpackers and my last stop was Home Depot. Alas, they didn’t carry them either. But when I was there I checked their tool boxes and found the perfect thing, a Stanley Mobile Tool Chest, more commonly called a Job Box because they are intended to be left at the job site. They have heavy plastic with metal hinges and locking clasps Best of all it was 50 gallons and very large! I had brought the measurements for the Hitch Haul so I checked and it would fit perfectly! However, sitting beside it was a Husky brand that was very similar to the Stanley but it cost less, $59. It looked to be every bit as good as the Stanley and it was $10 less so I bought it. http://www.homedepot.com/s/husky%20mobile%20tool%20chest?NCNI-5
The Job Box open, it's BIG! Notice very solid metal latches so it locks securely .

The Job Box open, it’s BIG! Notice very solid metal latches so it locks securely .

I took it home and sat it up on the Hitch Haul and it had a lot of room left over so I decided to empty one of my Rubbermaid Actionpackers and put it on the other end. It fit perfectly as well! I hadn’t even thought about the problem with the license plate but the Husky Job Box was so tall it would cover the license plate. So I slid it all the way over to the far side of the cargo carrier and put the Actionpacker under the license plate and it was low enough for the license plate to be clearly visible. That left a gap between the two boxes and then it occurred to me that my 5 gallon water jug would fit exactly in there so I grabbed it and it did. Perfect! The only thing left was to find a way to mount the boxes securely to the Hitch Haul. That was going to be easy because I had mounted the Actionpackers to two different motorcycle racks and to the tongue of my cargo trailer so I knew exactly what to do. If you can’t find one in your area, you can get them from Amazon here: Rubbermaid ActionPacker Storage Box, 24 Gallon
Looking into the Actionpacker after it's bolted on. The large washers are essential to keep the plastic from cracking. I've owned this box for probably 20 years and mounted it on two different motorcycles. They are well worth their cost!

Looking into the Actionpacker after it’s bolted on. The large washers are essential to keep the plastic from cracking. I’ve owned this box for probably 20 years and mounted it on two different motorcycles. They are well worth their cost!

I sat them up on the rack where I wanted them to be and took my drill and drilled holes up from underneath. Then I pushed two inch bolts through the holes. The single most important thing is to use large 1 inch fender washers on both the inside and outside of the bolts so the stress is distributed and doesn’t crack the plastic. I also used lock washers so they didn’t unscrew from the vibration of driving. Mounting the two boxes was very easy and probably only took 30 minutes.
Looking up from the bottom of the Hitch Haul at how I mounted it. You MUST have the wide fender washer to keep it secure.

Looking up from the bottom of the Hitch Haul at how I mounted the Job Box. You MUST have the wide fender washer to keep it secure.

In the pictures you’ll see that I put a heavy ratchet strap from the bumper around the Hitch Haul. The reason I did that was because one problem all items that mount into the receiver hitch have (except trailers of course) is they wobble around. The receiver hitch has to be large enough so the bar slides in and out easily and that extra room allows the item to shake around. The ratchet strap gives the Hitch Haul two more attachment points so it doesn’t sway. It worked very well and the cargo carrier was rock solid. I had some padlocks on hand that worked on the boxes so that was it, job done!
The boxes worked extremely well! The Husky job box was huge and swallowed up a massive amount of stuff! It also proved to be totally dust and water proof and neither ever got inside of it even though we drove through a lot of rain and dust. With the heavy plastic and steel hinges and lock hasps I never once worried about anything being stolen, and of course nothing was. The Actionpacker worked fine, but not as well. I’d had this one for a long time and it had spent a lot of time on my motorcycle and one of the ends around the hasp had slightly cracked. It leaked in a small amount of dust and water but not enough to do any harm. Just to be on the safe side we didn’t put anything in it that would have been damaged by water or dust. Don’t take that as a condemnation of Actionpackers, I’ve owned them for years and they never leaked until I cracked the hasp.
One of the things we had been concerned about is the Hitch Haul dragging on low spots. Judy’s van is a half-ton and we’d loaded it heavy enough to sag a little in back but even so I doubt it dragged more than a few times on the whole trip. If you followed the trip on my blog you know we camped many times off road and I thought it would drag often, but it almost never did. We went wherever we wanted without giving it a thought. It is well-designed and has a rise coming out of the receiver so it sits higher than the bumper.
When we got home we took it off Judy’s van and put it on mine and because it’s a 1 ton it is higher than Judy’s van and I doubt there is ever a time when it will drag on my van. One other thing I thought when we put it on my van is that I don’t believe it will hurt my stealth ability at all. On Judy’s van it was obvious that we were travelers and looked like tourists. But on my white cargo van with its ladder rack and ladder on the roof the big tool box on the back actually made it look more like a work van.
We found the boxes to be the ideal base to cook from.

We found the boxes to be the ideal base to cook from.

One other thing we liked a lot about the box on back is it made a great cook surface. Judy’s 2-burner propane stove fit inside either box so we stored it in there and then took it out and cooked right on the box. That worked very well! It gave us a lot of work surface and it was a perfect height.
The bottom line is for a couple in a van the Hitch Haul and job box is the perfect solution with very few disadvantages. And even for single people it is still a great idea and will clear a lot of stuff out of your van and give you a lot more room. Highly recommended!