How-To: Cargo Drawers (2000 - 2004)

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

How-To: Cargo Drawers (2000 - 2004)

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