I’m trying to make myself useful as I wait for machine shops to finish my parts… so I figured what better time to solve the “loose jack in the trunk” problem. I’ve never seen an early jack case/box in person, and have only seen one bad picture of one. I used the drawings from the ASM as a guide along with my knowledge that the box is styrofoam and the wrap is black cardboard….

I started with the foam project pieces from Home Depot. I used two.




First, I cut them in half, making four pieces 1’x2’. I used three for the project. I bought a styrofoam cutter that melts the styrofoam - if you do this, buy one with a sharp, narrow blade, not the Harbor Freight thick blade. You’ll get a better cut edge.





Then I laid out the jack as per the ASM drawing and traced around them with a Sharpie.





I used 3M spray adhesive to glue the traced piece and a second together. It only took about 5 minutes until they were solid and ready to cut. This is where a heated knife will be the only way to cut, unless you have a large scroll saw or other expensive cutting tool.






After test fitting, I laid the bottom piece under the top cut sections and traced the location of the jack handle. In drawings it seems to go through the jack hook and then underneath the jack assembly, so it needs a “ditch” to lie in.






Then a quick test fit and I glued the top and bottom sections onto the base piece.





I could see and test that the piece was about 3/4” too wide and an inch and a half or so too deep. Trimming on a table saw was easy and quick to get the perceived shape I saw in the ASM drawings. I flattened the ends and angled the top and bottom. If you have any rough edges, this foam sands very well with 120-150 grit sandpaper. I used that to smooth a number of the melted cuts.




For the case wrap, I bought a black cardboard table top display at Staples - being not that far removed from my son’s science fair projects. Lopping off the end pieces leaves a perfect 2’x3’ piece. I laid that face down on the counter, trimmed off about 3/4” of the width to match the insert, then folded the crease lines using a T-square edge. I worked around the insert leaving it just slightly loose so that the pieces could slide off each other easily. I used Gorilla glue to hold the overlapped edge in place and weighted the box edge for about 30 minutes.





The final fit and finish as I inserted the tools and slid the cover on - now all I need to do is get my back seat into place and tidy up the trunk before slipping this where it belongs.



My caveat here: I measured nothing and I have never seen a real case in my life! I *think* this box that I made *may* be too thick, and that the bottom piece maybe should be a half inch thick rather than an inch. But if I had to make one again, I know it only takes a couple hours and about $20 worth of stuff.

 

Nice work for a really hard to find part.

The originals wrapped around the styrofoam with the cardboard ends butted together about midway across one of the wide sides. The butted ends were held together with a piece of reinforced shipping tape about 3" wide.

I lucked up years ago and found a jack case in a junkyard Toronado. The cardboard was shot but the styrofoam was good, so I found a big corrugated cardboard box and made a slipcase. I never knew cardboard could soak up so much paint.

You realize there's a market for these, right?🙂
Especially since a lot of Toronado owners don't even know about them.

 

Very cool! 😎

I'd suggest carrying a scissors or floor jack in addition to the bumper jack, just in case.

 

This my original inner jack accessories holder with a new card board sleeve I had made.
All I have to do now is apply the decal and wax the sleeve like to original.

 

GREAT info in this thread, and WOW to actually see one in great shape! I'm wondering if I'll happen across one - or parts of one - at Lansing this year. These pics above could certainly result in another prototype box being made later this month... It's no wonder they put the sticker on the outside of this cardboard wrap - I stared at the box I made and I was tempted to tear it open lol I am taking a few minutes this afternoon to try and reproduce the sticker on some address label stock. The reproduction is great, but $7.00 shipping makes me choke... Thanks you guys for chiming in here