Well I guess I had better get this posted, been meaning to do it for ages.
At the same time I've been putting it off, I don't know why.
I started these drawers with Vern in March 2007 and I still haven't finished them by March 2008, sheesh.
In 2007 we did the side boxes but never really completed the drawers, just as well really as we changed our mind on how we were going to do the actual drawers.
The goal was to have side storage as well as a central set of drawers. There will be spaces between the central drawers, the side storage, and the rear cargo barrier for bits and pieces that won't fit in the drawers. The entire thing will be covered over and lockable so we can have our doggies sitting happily on top of it all when travelling.
Step 1 was to get a suitable template for the sides of the side boxes.
A full size PDF of our template can be downloaded from the website
here (1Mb PDF). If you print it out A3 it will be the same size as the one we used.
Step 2 was to do some slicing and dicing. For our material we choose to use 3-ply marine bonded plywood. Strong, resilient, and should be more than suitable to the task at hand.
Step 3 was to create some floor and side panels using wood-glue and screws to hold them together. This helps to give structural strength to the box.
Step 4 was to add a lid. We're not sure if we're gonna keep this size lid or (re)move it when we create the centre bit with the drawers, so we'll see how we go. We used stainless piano hinges to hold the lid on.
Step 5 was to put it in place
Step 6 was to take them home and paint them up to protect the wood. I used an all-in-one water-based paint and got some anti-mould stuff and mixed it in with it. First coat I thinned out with water so it soaked into the wood better, second coat finished it off. Sorry no pics of that as it's a pretty rough looking paint job to say the least :-|
Originally the side boxes weren't secured by a couple of weekends ago Vern and I finished off some mounting brackets so they can be snugly bolted to the vehicle
Now for the actual drawers themselves, the tricky bit.
We used a metal framework using 25x25 RHS and 25x50 RHS. Both oversized, but what we had.
Timber is 18mm 5 ply.
Woodworking machine is cast iron 10inch tablesaw with router table extension.
Sturdier but less portable than triton.
We also used a jigsaw and a belt sander.
Job could be done with jigsaw and hand saw for straight cuts.
So you wouldn't need expensive equipment, just easier if you have it.
The metal stuff could be done with timber as well.
Woodworking machine is cast iron 10inch tablesaw with router table extension.
Sturdier but less portable than triton.
We also used a jigsaw and a belt sander.
So we start out with some left over metal
As you can see in this photo we used the wider metal (25x50 RHS) for supporting the sides...
Test fitting for sizing of the roof piece
Almost completed framework
Some tidying up
Adding the securing plates
A coat or two of paint
Complete with drawers
Done!
(actually I still have to make the lids of the side boxes and give them another coat of paint... but close enough for now)