Assembling the Weather Guard 42" x 60" x 16" Heavy Duty Van Shelf

Deeper shelves change how you plan a van build. The Weather Guard heavy duty van shelf gives you 16" of depth on three of its four shelves, enough for bigger bins, cases, and Packout gear. It also mounts a little differently from standard Weather Guard shelves. In this guide we plan the layout, then assemble the 42" wide unit step by step.

Weather Guard Heavy Duty Van Shelf: What We're Building

We're assembling the Weather Guard Heavy Duty Adjustable 4-Shelf Unit – 42" W x 60" H x 16" D (Model 9364-3-03). Three shelves are 16" deep, and the top shelf is 13.5" deep to fit the taper of the end panels. Most standard Weather Guard shelves are 13.5" deep, so this unit is noticeably beefier.

Our shelf is headed for a Ford Transit, with drawer units on the bottom and a lockable door compartment above them. This video covers assembly only; the in-van install is coming in a separate video.

Start by scanning the QR code on the one-page sheet in the box for Weather Guard's latest assembly and installation instructions. That's the ultimate source of information.

Plan your layout before you build

Wheel well clearance

If the shelf sits over a wheel well, the lowest shelf has to clear it. On standard Weather Guard shelves, the bottom shelf typically goes at hole location 4 for the Ford Transit and Mercedes-Benz Sprinter, and location 6 for the RAM ProMaster.

The heavy duty difference: on this unit, the holes start one location higher than on standard shelves, so you effectively lose the first mounting hole. For our Transit, that means the bottom shelf goes at location 3.

Spacing for doors, back panels, and drawers

Accessories need specific gaps between shelves:

• Shelf doors and back panels: 7 hole increments
• Drawer units: 9 hole increments, counting the hole where the lower shelf mounts

We're running two drawer units side by side on the bottom shelf, then a door and back panel on the shelf above for a secure compartment. The top shelf goes in the top position.

What you'll need

• The small hardware bag of bolts. That's all assembly takes. Save the larger bag of brackets and hardware for the van install
• A power drill or driver
• A square
• Cardboard to protect the end panel. A flattened box top works

Step-by-step assembly

Step 1: Lay out the first end panel

Set one end panel flat on the cardboard to prevent scratches. You'll build the shelves onto it, then cap it with the second panel.

Step 2: Seat the 13.5" top shelf

The narrower 13.5" shelf goes at the top, where the end panels taper. Lances at the top of the end panel slide into slits in the shelf. If paint or a stiff tab gets in the way, a light tap usually seats it.

Step 3: Work from the bottom up

Install the bottom shelf at your wheel well location. Standard orientation is flanges up, with slits for the included dividers. You can also flip a shelf for a flush top surface, which is common on 16" shelves for mounting Packout feet or clips.

Use one bolt in the front and one in the back. Hand-thread each bolt into the pressed-in captive nuts first so you don't cross-thread them, and leave them just tight enough to hold the panel upright.

Step 4: Add the middle shelves

Set the next shelf at your accessory spacing: 9 hole increments for drawers, then 7 for a door and back panel above that.

Step 5: Cap it with the second end panel

Rest the second end panel on top, make sure the top shelf slides into its lances, and bolt each shelf into the same holes you used on the first panel.

Step 6: Square it and tighten

Lightly assembled, the unit has some flex and can easily end up cockeyed. Check it with a square, then tighten every bolt with your power tool.

Before it goes in the van

Stand it up carefully. The unit weighs about 100 pounds. If all that weight lands on one leg as you tip it upright, the leg can bend.

Install accessories now. Drawers, doors, and back panels are much easier to install with room to get behind and under the shelf. Do it before the shelf goes into the van. See our installs of the 3-drawer cabinet and the 2-drawer cabinet on this exact shelf.

Pick your install method. Weather Guard includes brackets and hardware for a basic install with plus nuts in the van wall and floor. For a cleaner setup with more adjustment, a vehicle-specific mounting kit like the Ford Transit 148" WB kit mounts tracks to predetermined locations on the wall, and the shelf attaches to the tracks.

Shop the Weather Guard Heavy Duty Adjustable 4-Shelf Unit – 42" W x 60" H x 16" D

Need a wider unit? There's a 60" x 60" x 16" heavy duty version. Browse all van shelving.

FAQ

What makes this a heavy duty shelf?
Three of its shelves are 16" deep, compared to 13.5" on most standard Weather Guard shelves. The top shelf is 13.5" deep.

Why does the bottom shelf go one hole lower on a Transit?
On the heavy duty unit, the holes start one location higher than on standard shelves. Location 3 on this shelf gives the same wheel well clearance as location 4 on a standard shelf.

How should I space shelves for drawers?
Leave 9 hole increments, counting the hole where the lower shelf mounts. For doors and back panels, use 7.

Which hardware do I need for assembly?
Only the small bag of bolts. The larger bag with brackets is for installing the shelf in the van.

Should I add drawers before or after installing the shelf?
Before. You'll have room to reach behind and under the shelf, which is much harder inside the van.

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