Building a Custom Ski Box for an Adventure Travel Van
When you’re chasing fresh snow and rugged backcountry trails, your gear needs to travel safely and securely. Recently, I had the chance to fabricate a custom ski box for an adventure travel van, designed to hold up to six sets of skis or snowboards along with essential backcountry gear. This project combined craftsmanship with durability, ensuring the box could handle harsh winter conditions while being easy to use on the go. From marine-grade plywood construction to a sturdy steel mounting bracket, every detail was built for function, security, and adventure.
Crafting the Box: Durable, Lightweight, and Weather-Resistant
The heart of the project was building the box itself—a secure storage solution made from marine-grade plywood. This material was chosen for its ability to withstand moisture and extreme conditions without warping or degrading, making it ideal for winter use. I cut the panels to size, reinforced the edges, and sealed the entire structure to provide long-lasting protection against snow, rain, and road grime.
To keep gear safe, I installed heavy-duty locking latches, giving the owner peace of mind during stops. Inside, the box was designed with dividers to keep skis, snowboards, and poles neatly organized. The spacious box is large enough to also accommodate backcountry gear such as avalanche float packs, helmets, poles and the ever-handy sturdy snow shovel to dig yourself out after a giant blizzard camping at the trailhead!
Welding the Steel Bracket: Strength and Versatility
The mounting bracket for the ski box was just as crucial as the box itself. I fabricated the bracket from steel, ensuring it could withstand the weight and stress of fully loaded gear on rough roads. The bracket mounted to the van by swapping out the standard 270 degree hinges with 180 degree hinges that include 2 holes that can be mounted to. This ensures that the load is safely carried and will not obstruct the access to the rear doors for gear loading or unloading.
After welding, the bracket was coated with Rhino Liner—a durable spray-on coating—to protect it from rust, salt, and abrasion. The coating ensures the bracket will remain in top condition through countless winters, no matter how tough the conditions get. Once mounted, the box and bracket combination felt solid, with no rattling or shifting during travel.
Adventure-Ready Design
The final installation transformed the back of the van into an adventure-ready storage system. The ski box not only keeps gear protected from the elements but also makes loading and unloading a breeze. Whether heading out for resort days or backcountry tours, the secure mounting and swing-open design mean no hassle at the trailhead.
This project was more than just a build—it was about creating a storage solution that aligns with the adventurous spirit of the van and its owner. By combining durable materials, thoughtful design, and skilled fabrication, this custom ski box ensures that gear is always organized, accessible, and protected for every snowy adventure ahead.
