Finding the Right Overland Cargo Box: Comparing Storage Options for My Jeep Gladiator
Finding the right waterproof storage box for my Jeep Gladiator bed rack turned into a bigger project than I expected. Here’s what I learned comparing Pelican, VEVOR, Eylar, Plano, and several other options — and why I ultimately purchased the one I did.
When You’re Out of Room but Not Out of Ideas
Building an overland rig is a process of constant refinement. At least, that’s been my experience building out Gladiator Stoked, my 2021 Jeep Gladiator Mojave.
I’ve spent the last few years figuring out what I actually need on the trail, what I can live without, and how to organize the gear I’ve accumulated along the way.
My existing storage system works pretty well. I’ve got dedicated camp kitchen and general camping boxes, a trail bag, and storage inside the cab for recovery equipment and other essentials. It’s a modular system that lets me load only the equipment I need for a particular trip.
But as my adventures have grown into longer, multi-night excursions, I’ve run into a familiar problem: I need more storage without turning the Gladiator into a rolling storage shed.
The next logical place to expand was the bed rack.
My homemade rack uses dimensional lumber and Unistrut crossbars, with a Roofnest Meadowlark rooftop tent occupying most of the available space.
Along the passenger side, however, I had a narrow strip of usable real estate. With some adjustments, I figured I could accommodate a cargo box approximately 16 inches wide, with enough clearance to open the lid and access its contents from beside the truck.
The goal wasn’t simply to find another waterproof container.
I needed something that would fit the space AND solve my storage expansion problem.
That distinction eliminated a surprising number of otherwise excellent cases.
What I Was Looking For
Before shopping, I established a handful of requirements.
- Footprint: Approximately 15-16 inches wide, preferably around 48–54 inches long.
- Capacity: Enough usable depth for bulky camping equipment, additional food, clothing, and other overflow. (12-15 in.)
- Weather protection: A sealed enclosure suitable for rain, road grime, and dusty trails.
- Security: Lockable access and a way to secure the box to the rack.
- Accessibility: A lid configuration that works beside the rooftop tent.
- Appearance: Clean, understated, preferably black, and without enormous logos.
- Budget: Ideally around $350 or less.
That last requirement mattered because this was an incremental upgrade to an existing system, not a complete storage rebuild.
With those parameters established, I started researching.
The Cases That Made My Shortlist
1. Pelican Vault V770 — The Long, Lean Contender
Pelican was an obvious starting point.
The Vault V770 is a long, narrow protective case primarily designed for transporting a rifle, but its shape initially caught my attention for rack-mounted storage.
At approximately 51.5 inches long and 13.2 inches wide, it appeared to fit my available footprint remarkably well.
The problem was its depth.
With only about six inches of usable interior height, it simply wasn’t going to swallow the kind of bulky gear I wanted to relocate out of the cab or truck bed.
It would make an interesting storage option for recovery equipment, tools, or long, relatively flat items. But it wouldn’t solve my expansion problem.
My takeaway: Excellent footprint, insufficient storage depth.
[AMAZON AFFILIATE LINK — PELICAN VAULT V770]
2. Pelican Cargo BX55S and BX85S — Purpose-Built for Adventure
The Pelican Cargo line was arguably one of the best-looking options in my search.
These are rugged, weather-resistant cargo cases designed with mounting systems for truck beds and roof racks.
The BX55S measures approximately 36.6 inches long, while the BX85S stretches to 56 inches. Both are only about 13 inches wide and 11.5 inches tall.
That narrow profile is appealing when you’re squeezing additional storage alongside a rooftop tent.
The larger BX85S offered the long footprint I wanted, although its 56-inch length was pushing my available space.
But the real issue was interior geometry. Both cases have an interior width of roughly eight inches and just over eight inches of depth.
That’s a great configuration for carefully selected equipment. It’s less appealing for an assortment of camping supplies, clothing, extra food, and whatever else might need a place to ride.
They’re purpose-built adventure cases, and I can appreciate that. They simply weren’t the right solution for my particular mission.
My takeaway: Attractive, purpose-built cargo cases, but too narrow inside for the way I wanted to use them.
[AMAZON AFFILIATE LINK — PELICAN BX55S]
[AMAZON AFFILIATE LINK — PELICAN BX85S]
3. Pelican CRATE 90L — The Premium American-Made Contender
Now, this one really got my attention.
The Pelican CRATE 90L combines rugged protective storage with a modular design that makes a lot of sense for overlanding.
First, there’s the Pelican name.
Brand recognition and American manufacturing were huge pluses for me. Pelican has spent decades building a reputation for protective equipment, and knowing this particular product is made in the USA made it even more appealing.
The CRATE also comes with some especially interesting features:
- 90 liters of storage capacity
- IP67-rated protection against water and dust
- A multi-position lid that opens from either side or can be removed
- Integrated ModRail mounting and accessory system
- Padlockable hasps
- Stackable design and configurable organization accessories
I particularly liked the dual-side-opening lid. That’s a genuinely useful feature for a case mounted alongside a rooftop tent, where opening direction can make or break the installation.
Unfortunately, the CRATE’s dimensions weren’t quite right.
At approximately 32.2 inches long and 20.2 inches wide, it was shorter and wider than I wanted. Although it offered excellent versatility, it would require more lateral space than I had planned to dedicate to the storage box.
And at 90 liters, its capacity was considerably smaller than that of the box I ultimately purchased.
My takeaway: One of my favorite designs in the entire search, especially because it’s American-made and backed by Pelican’s reputation. But it didn’t fit my available footprint or capacity goals.
[AMAZON AFFILIATE LINK — PELICAN CRATE 90L]
4. VEVOR Large Waterproof Storage Case — Getting Closer
At this point I started looking beyond traditional premium protective-case brands.
VEVOR offers a broad catalog of tools, storage equipment, and workshop products, including large protective cases.
One of the larger waterproof equipment cases I considered offered approximately 44 inches of length and a width in the neighborhood of 16 inches.
Now we’re talking.
This was much closer to the proportions I wanted, and the larger case designs offered more practical storage space than the shallow rifle-style cases.
But I still had reservations about the overall configuration, available dimensions, and how well the case would integrate with the rack.
Some of these products are designed primarily for protecting specialized equipment rather than serving as everyday camping cargo boxes.
I was also trying to balance useful capacity against the cost and complexity of mounting something securely.
My takeaway: A practical, more affordable direction, but not quite the right combination of footprint, access, and capacity.
[AMAZON AFFILIATE LINK — VEVOR LARGE WATERPROOF CASE]
5. Elite Edge 39-Inch Steel Toolbox — The Contractor Option
Traditional pickup-truck toolboxes offered another possibility.
The Elite Edge 39-inch steel box I considered was roughly 16 inches wide and 14 inches tall, making its overall dimensions attractive.
The appeal was obvious: plenty of room, a lockable enclosure, and a product specifically intended for truck storage.
Unfortunately, there were several compromises.
Steel construction meant additional weight mounted relatively high on the truck. The lid arrangement wasn’t especially attractive for my rack configuration, and the overall appearance felt much more like a contractor’s toolbox than an overland equipment case.
There’s nothing wrong with that, of course. Plenty of capable adventure vehicles carry conventional truck boxes.
But I wanted something that looked and functioned like it belonged on Gladiator Stoked.
My takeaway: Functional storage capacity, but too heavy and industrial-looking for my preferred setup.
[AMAZON AFFILIATE LINK — Elite Edge 39-INCH TOOLBOX]
6. Eylar XL Protective Case — An Interesting Alternative
Eylar manufactures protective hard cases for equipment, firearms, photography gear, and outdoor use.
I looked at one of its longer, deeper rolling-case configurations as an alternative to the Pelican Vault.
Eylar offers a range of rugged cases, many incorporating gasket seals, reinforced construction, and lockable closures.
The attraction was finding a relatively narrow protective case with more interior depth than the typical rifle case.
There were some promising options, but the same fundamental challenge kept appearing.
The dimensions were close without being ideal, and the equipment-case layout wasn’t necessarily the most efficient way to store loose camping supplies.
My takeaway: Worth considering when you need protected storage for equipment, but not my preferred solution for general camp-cargo expansion.
[AMAZON AFFILIATE LINK — EYLAR XL CASE]
7. Plano Sportsman’s Trunk — The Budget Benchmark
I already own and use large Plano Sportsman’s Trunks as part of my camping system.
They’re inexpensive, practical, and surprisingly useful for organizing a lot of equipment.
In fact, much of my camp kitchen and general camping system has been built around large storage bins like these.
So why not just mount another one?
For starters, their dimensions weren’t ideal for the narrow space alongside my rooftop tent.
And although they’re useful storage containers, they are not weather proof and I wanted something better suited for a permanently mounted, lockable, externally exposed installation.
Plano trunks are still part of my kit. They just weren’t what I wanted for this particular application.
My takeaway: Excellent value for modular bed storage, but not the right permanent bed-rack box.
[AMAZON AFFILIATE LINK — PLANO SPORTSMAN’S TRUNK]
The Winner: Joytutus 160-Quart Lockable Truck-Bed Toolbox
After all that research, I found a product that approached the problem from a slightly different angle.
Instead of another conventional overland protective case, I purchased the 160-quart lockable truck-bed toolbox from Joytutus.
And the capacity caught my attention immediately.
At 160 quarts — approximately 151 liters — it offers considerably more advertised storage volume than the Pelican CRATE 90L.
The manufacturer’s published exterior measurements are approximately 49.8 inches long, 16.7 inches wide, and 15.8 inches tall.
That’s remarkably close to the footprint I had been trying to fill.
Other features that helped make the decision included:
- Weather-sealed construction with rubber gaskets
- Integrated locking system
- Approximately 45.8-pound empty weight, admittedly heavy for a box mounted high. I’ll need to consider this when packing contents.
- Separate storage areas for bulky items and smaller accessories
- Two removable MOLLE organization panels
- Black exterior
- A form factor intended for pickup-truck cargo storage
Best of all, it promised a meaningful increase in available storage rather than simply moving a few smaller items from one container to another.
I paid $284 for mine.
That put it comfortably within my budget, although I recognize that purchasing a box is only part of building a safe and functional mounting system.
[AMAZON AFFILIATE LINK — JOYTUTUS 160-QUART LOCKABLE TOOLBOX]
Why I Chose It
The answer comes down to available volume, usable shape, and the ability to adapt my existing rack.
The Pelican CRATE was an especially appealing premium option. The Pelican Cargo cases looked fantastic and had purpose-built mounting possibilities. And several of the less expensive alternatives offered reasonable capacity.
But I couldn’t find another option in my shortlist that combined the dimensions and advertised volume of the Joytutus in a way that suited what I was trying to accomplish.
That doesn’t automatically make it a better box.
It makes it the box I chose for this particular project.
And there’s an important difference.
Lessons Learned Shopping for Overland Storage
One thing this project reinforced is that storage capacity alone doesn’t tell the whole story.
A 50-inch-long protective case might look enormous in a product photograph, but if its usable interior is only six inches deep, it may not offer much space for ordinary camping equipment.
Likewise, a rugged 90-liter container with excellent features might be a poor fit if it consumes too much width on an already crowded rack.
And even the box with the most attractive specifications might require additional work before it’s ready for trail use.
I learned to pay closer attention to three measurements: exterior footprint, usable interior dimensions, and the clearance necessary to operate the lid.
The other important lesson was to define the storage problem before choosing the product.
I wasn’t trying to build a permanent home for expensive camera equipment or delicate electronics.
I wasn’t looking for a rifle case.
And I didn’t need a box that merely duplicated my existing camp-kitchen or gear-bin system.
I wanted more usable cargo space without sacrificing the equipment and layout I already liked.
That was the real buying criterion.
Honorable Mention: ROAM Adventure Co. — Great Designs, Premium Prices
I also gave serious consideration to the rugged cargo cases from ROAM Adventure Co..
I’ll give ROAM credit where it’s due. They make some of the best-looking overland storage boxes on the market. Their cases have a clean, purpose-built appearance, attractive color options, weather-resistant construction, and an impressive lineup of mounting hardware and accessories.
The 83L, 95L, 105L, and 160L cases were particularly interesting. These are products clearly designed with the overlanding community in mind.
But there’s one issue I couldn’t get past: the price.
With some cases running $400–$525 before additional mounting hardware or accessories, ROAM is firmly in premium territory.
There are also reports that ROAM’s cases are manufactured in China, although I wasn’t able to independently verify the country of origin for every model.
Now, I have nothing against Chinese manufacturing. Plenty of excellent outdoor equipment comes from China, and there’s certainly some on my own rig. But when a company charges premium prices for an imported storage box, I start looking very closely at what I’m getting for my money.
At those prices, I’d be more inclined to spend my money on an American-made Pelican product with an established reputation in protective equipment.
ROAM deserves an honorable mention for its attractive designs and extensive accessory ecosystem. But between the pricing and my particular space requirements, I couldn’t justify the investment.
My takeaway: Some of the nicest-looking cases in overlanding, but the value proposition didn’t work for me.
[AMAZON AFFILIATE LINK — ROAM 95L RUGGED CASE]
Honorable Mention: Overland Vehicle Systems — Another Premium-Priced Contender
Another brand that caught my attention was Overland Vehicle Systems (OVS).
Like ROAM, OVS offers some attractive, purpose-built storage solutions for the overlanding market. Their D.B.S. dry boxes come in several capacities, including 95, 117, and 169 quarts, with features such as durable construction, secure closures, and provisions for organizing outdoor gear.
I particularly liked the clean styling and the fact that OVS offers an entire ecosystem of vehicle storage and adventure equipment.
But once again, I struggled with the value proposition.
With some models priced above $300, I was looking for more than a recognizable overlanding brand and attractive styling. I wanted maximum usable capacity, practical dimensions, and a product that justified the investment.
Manufacturing origin also plays into that calculation. I’m not opposed to buying Chinese-made equipment — I already own plenty — but I place a higher value on American manufacturing when comparing products in the premium price range. I couldn’t independently confirm the country of manufacture for every OVS storage box, so that’s something I’d want clarified before making it a deciding factor.
Ultimately, the OVS options didn’t offer a compelling enough combination of dimensions, storage capacity, and price to displace the Joytutus I purchased.
My takeaway: Good-looking, adventure-oriented storage solutions, but the particular options I considered didn’t offer enough additional value for my application.
[AMAZON AFFILIATE LINK — OVERLAND VEHICLE SYSTEMS D.B.S. STORAGE BOXES]
Final Thoughts: Buy for the Mission, Not the Badge
I’ll admit that I was initially drawn to the premium Pelican options.
The CRATE 90L, in particular, checked a number of boxes in terms of American manufacturing, brand reputation, innovation, and overall design.
I could easily imagine using one in another part of my camping system.
But this particular purchase wasn’t about owning the most recognizable case on the rack.
It was about solving a problem.
After comparing a long list of possibilities, I settled on the Joytutus 160-quart truck-bed toolbox because its size, capacity, and price gave me the best starting point for the expansion I had in mind.
Whether it proves to be the ideal long-term solution will depend on the installation and how it performs on the trail.
I’ll share those results after I’ve had an opportunity to put the setup to work.
Until then, here’s the conclusion I’d offer anyone looking for more storage on an overland vehicle:
Measure your available space, define exactly what you want to carry, and choose the box that serves that purpose — even if it isn’t the one you originally expected to buy.
HERE’S TO THE ROAD UNPAVED – DOUG.
Affiliate Disclosure
As an Amazon Associate, I earn from qualifying purchases. Some product links in this article may be affiliate links, which means I may earn a small commission if you make a purchase, at no additional cost to you. I purchased the Joytutus cargo box with my own money, and the opinions expressed here reflect my independent research and purchasing decision.