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Discussion Starter · #1 · (Edited)
A few people have asked me for the design of my Cargo Drawers. I'm finally getting around to writing up the design drawings and organizing the basic photos.
Unfortunately I don't have photos of every step along the way.

I make the assumption that you can at least put together Ikea furniture (simple drawings and parts connect together with no instructions) and know how to use a table saw and router (optional).

Instructions:
• Cut foam-core to match Rail pattern
• Test fit in cargo area
• Adjust dimensions accordingly
• Layout primary pieces (everything *except* flaps and fascia)
• Cut out pieces
• Layout rabbits, dados and general grooviness
• Cut that stuff out
• Test fit (dry)
• Make adjustments
• Begin assembly. (use glue on all edges, nail or screw as you see fit)
• Fit completed cabinet box in cargo area
• Measure and mark-up foam-core for left and right flaps
• Repeat for drawer fascia
• Cut that stuff out
• Attach flaps with piano hinge
• Attach drawer fronts with screw
• Epoxy if desired (I epoxied the cabinet tops and drawer interiors for water resistance)
• Cover the cabinet with carpeting (if desired)

First cut templates (I went ahead and cut the rails and the rough for the flaps.

IMG_1605.JPG by sionnach_tbg, on Flickr


IMG_1606.JPG by sionnach_tbg, on Flickr


IMG_1608.JPG by sionnach_tbg, on Flickr


Then I cut the basic shapes and test fit those. (note: I got a great deal on cabinet grade plywood at Lowes)

IMG_1614.JPG by sionnach_tbg, on Flickr


IMG_1615.JPG by sionnach_tbg, on Flickr


Then a friend and I cut out the rabbits and dados, fit things together and screwed in the flaps (whole bunch of steps not photographed (all the basic cutting, but you guys are schmart, you can figure it out))

IMG_1643.JPG by sionnach_tbg, on Flickr


IMG_1644.JPG by sionnach_tbg, on Flickr


Put together drawers, attach to drawer slides, test fit in the Xterra again:

IMG_1645.JPG by sionnach_tbg, on Flickr


IMG_1646.JPG by sionnach_tbg, on Flickr


Then I cut the drawer fascia boards and fit the handles:

IMG_1682.JPG by sionnach_tbg, on Flickr


IMG_1683.JPG by sionnach_tbg, on Flickr


Then I took everything out and epoxied the inside of the drawers and the top of the cabinets:

IMG_1722.JPG by sionnach_tbg, on Flickr


IMG_1718.JPG by sionnach_tbg, on Flickr


IMG_1719.JPG by sionnach_tbg, on Flickr


IMG_1720.JPG by sionnach_tbg, on Flickr


IMG_1724.JPG by sionnach_tbg, on Flickr


Then get some carpet on that box:

IMG_1744.JPG by sionnach_tbg, on Flickr


IMG_1746.JPG by sionnach_tbg, on Flickr


And done:

IMG_1762.JPG by sionnach_tbg, on Flickr


Should be fairly straight forward. I've put together a PDF of the design with the dimensions. Let me know what questions you guys have or anything that could be clarified better.
If you do build this please let me know how it goes, take photos and I'll update the thread accordingly.

Also, if you build these and your friends love them, point them to the thread.

Thanks!

PDF here:
Xterra Cargo Drawers (2000-2004) PDF
 

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Nice writeup!!!!!! Love it!
 

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super clean set up. good job
 

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Nice job. Major props.
 

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Very nice.
 

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Discussion Starter · #8 ·

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I love this.. How does bedliner work on wood? I wonder what a box bedlines would be like.

Now how do you access your jack and wheel tools? Just tossed those into the box?
 

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Discussion Starter · #11 ·
I love this.. How does bedliner work on wood? I wonder what a box bedlines would be like.

Now how do you access your jack and wheel tools? Just tossed those into the box?
Bedliner works great on wood.
Check out Tembo Tusk and Adventure Trailers - they both use it.

For jack and stuff, yeah just in the drawer, though it'll get replaced by the hiLift and possibly a bottle jack
 

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I plan on having one done in the next month :D
How far are the drawers coming out in normal operation? Or, will they tip out easily without the box being secured to the X?
 

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Discussion Starter · #14 ·
@MosesM
These are turning out great so far.
:)

Mine are just a touch larger than the PDF plans (by about 1/8th inch) and the cabinets are very much wedged in and secure, nothing is lifting or tipping out.

I may decided to anchor to the bed, but that would be an easy operation.
 

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I cant wait to do that! Looks sharp! Is there any way you can repost the pdf or PM it to me? When i click the link it gives me an error code.thanks!
 

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Discussion Starter · #17 ·
I cant wait to do that! Looks sharp! Is there any way you can repost the pdf or PM it to me? When i click the link it gives me an error code.thanks!
Hey - thank you.

What browser are you using to try and go to the link?
I just tried it and
Got the PDF just fine. Or pm me your email address and I'll send it over.
 

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I was using piece of turd fire fox. I downloaded it through my phone and emailed it to my self.Ha. thanks though, and again, killer work!
 

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RoadWarrior - I would advise against Bedliner as the Bedliner especially in black would absorb a large amount of heat and cook whatever you were to keep in your drawers like a mini oven. The carpet is to prevent this from happening unless of course your trying to make an oven then that would be awesome.

Awesome. If I had any carpentry skills I would totally do this.
 
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