How-To: Cargo Drawers (2000 - 2004)

Sionnach

Bought an X
Founding Member
Location
Seattle
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


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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


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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:
XterraCargobblerawers_2000_2004_high.pdf
 
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Cameron23

Skid Plates
Founding Member
Location
Kansas
Wow looks great! I think in just gonna mount my craftsmen in there but this is definitely a cool idea maybe a thinner one for just like 3 drawers of tools or something.

Sent from my SAMSUNG-SGH-I897 using Tapatalk 2
 

ChiXterra

Wheeling
Dang, that is some serious craftsmanship. Notches in the wood and everything. I think I'll go a little more basic when I do mine, and possibly a tad lighter. I hate carpet, because everything sticks to it. I was actually thinking of the rubber boat deck material on the top, and perhaps bedliner on the front of the drawers. I also have a subwoofer, so I am going to add some additional holes to route the wires through.
 

Sionnach

Bought an X
Founding Member
Location
Seattle
@Roadwarrior -
My boxes are about 1/8th inch larger than the PDF design.
So mine are fairly wedged in pretty tight and don't seem to be going anywhere.

If I were to make it less tight I would probably mount it to the deck in the front and rear sides with some small wire and turnbuckle situation.
 

TKDx00

Lockers Installed
Founding Member
About to really get into making a version of this now...where did you get the carpeting...any carpet place will do or somewhere like a hobby store? And how much material did you get/use?
 

Sionnach

Bought an X
Founding Member
Location
Seattle
About to really get into making a version of this now...where did you get the carpeting...any carpet place will do or somewhere like a hobby store? And how much material did you get/use?


I picked up a 6' x 9' outdoor rug from lowes. its like $12 or so. works really good.
 

Sionnach

Bought an X
Founding Member
Location
Seattle
So - has anyone built these or used these plans this past summer? I am curious to know of any problems or modifications people may have done/run in to.
 

AZhiAZiAM

Suspension Lift
Location
Fresno,CA
i just sold my subs, and im about to try and build one. actually just got all the wood today. just waiting for my to get out of the shop.
 

Timrich

Super Duper Moderator
Founding Member
Location
Central FL
Mudchet (Kevin) had a nice set up in the back of his x. I got to take a peek at them at nxm.

Sent from my Galaxy S III
 

mudchet

Got Mud?<br><img src="http://i164.photobucket.com/
Founding Member
Location
Brentwood, TN
Mudchet (Kevin) had a nice set up in the back of his x. I got to take a peek at them at nxm.

Sent from my Galaxy S III

Thanks Tim. I will work on a write up for gen2 w dimensions if there is interest. A couple of differences between mine and sionach's : 1. He used expoxy to seal the wood. I love that idea and wish i ahd seen this post a few weeks ago. 2. I used the tracks in the cargo floor to bolt my box to the x. It's not going anywhere. 3. Instead of carpet, i covered mine with hdpe plastic. It adds weight, but is super durable. I attached hdpe to the plywood carcass so that i could swap out the plastic in a few years if it is really mangled. I figured the carpet would get full of mud, dirt and grease on my first outing and thus went the hdpe.

One question for sionnach: your drawer slides look really beefy. What weight are they rated to and where did you get them?
 

02Xterra

Wheeling
Location
Central VA
One question for sionnach: your drawer slides look really beefy. What weight are they rated to and where did you get them?

^^I have the same question

Im currently redesigning my current storage box and I'm planning on going with something similar to this one.. should start on it tomorrow!
 

TKDx00

Lockers Installed
Founding Member
HEY!!! I can't find the foam core you used. All I find is the 3" think flimsy seat cushion stuff and it's green. Where did you get yours? I need it to cutout the top. Everything else is done.
 
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Sionnach

Bought an X
Founding Member
Location
Seattle
I got mine at office max. I have also seen it at drug stores, with the poster board. Sometimes it's labeled as "presentation board".
 

Dodge

Test Drive
Location
Windsor Ontario
Great job they look awesome!

I was thinking of doing this after I get through the long list of other stuff I still need to do on the X. I might lighten it up with some Aluminum angle framing instead of wood. I'm sure these are handy!
 
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