How-To: Cargo Drawers (2000 - 2004)

Sionnach Apr 25, 2012

  1. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    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]
    IMG_1605.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1606.JPG by sionnach_tbg, on Flickr

    [​IMG]
    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]
    IMG_1614.JPG by sionnach_tbg, on Flickr

    [​IMG]
    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]
    IMG_1643.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1644.JPG by sionnach_tbg, on Flickr


    Put together drawers, attach to drawer slides, test fit in the Xterra again:
    [​IMG]
    IMG_1645.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1646.JPG by sionnach_tbg, on Flickr


    Then I cut the drawer fascia boards and fit the handles:
    [​IMG]
    IMG_1682.JPG by sionnach_tbg, on Flickr

    [​IMG]
    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]
    IMG_1722.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1718.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1719.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1720.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1724.JPG by sionnach_tbg, on Flickr


    Then get some carpet on that box:
    [​IMG]
    IMG_1744.JPG by sionnach_tbg, on Flickr

    [​IMG]
    IMG_1746.JPG by sionnach_tbg, on Flickr


    And done:
    [​IMG]
    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
     
    Last edited: Apr 25, 2012
  2. Cameron23

    Cameron23 Skid Plates Founding Member

    Messages:
    1,486
    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
     
  3. Timrich

    Timrich Super Duper Moderator Lifetime Member Founding Member

    Messages:
    2,429
    Location:
    Central FL
    NIce write up sir! Rep points for you!
     
  4. myXiswhite

    myXiswhite Test Drive

    Messages:
    45
    Location:
    Simi Valley, CA
    how heavy is this thing?? I would like to do this but IDK about adding too much weight back there
     
  5. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    Location:
    Seattle
    I'd say just a little over 50lbs.
    Given that it's pretty much just a 4x8 foot sheet of plywood.
     
  6. Fisherman John

    Fisherman John Test Drive

    Messages:
    12
    Location:
    Cleveland, Ohio
    Soooo much more professional than mine. I think I will make a new one according to your specs.
    Thanks this is awesome!
     
  7. myXiswhite

    myXiswhite Test Drive

    Messages:
    45
    Location:
    Simi Valley, CA
    ok 50 pounds isnt bad it looks great btw!
     
  8. J Everett

    J Everett Suspension Lift Supporting Member Founding Member

    Messages:
    2,601
    Location:
    Houma, LA
    50# isn't bad at all. It looks much heavier than that. Great job!
     
  9. ChiXterra

    ChiXterra Wheeling

    Messages:
    520
    Location:
    Northern Illinois
    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.
     
  10. Roadwarrior

    Roadwarrior Titan Swapped / SAS'd Founding Member

    Messages:
    5,475
    Location:
    Probably in class..
    I am looking to do this over the summer.. but I must ask, how did you mount this to the back of the X? or does it just sit there?

    Mounting ideas?
     
  11. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    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.
     
  12. Roadwarrior

    Roadwarrior Titan Swapped / SAS'd Founding Member

    Messages:
    5,475
    Location:
    Probably in class..
    I was just wondering if you had removed the cargo tie downs and bolted it to those locations or not

    Sent from somewhere by something
     
  13. TKDx00

    TKDx00 Lockers Installed Lifetime Member Founding Member

    Messages:
    2,075
    Location:
    S.Subs of Chicago, IL.
    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?
     
  14. Xterra Performance

    Xterra Performance Sliders

    Messages:
    848
    Location:
    MOORPARK
    WOW, that is a really nice box. Let me know if you ever want to go into business building them!

    ;0
     
  15. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    Location:
    Seattle

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

    Sionnach Bought an X Founding Member

    Messages:
    79
    Location:
    Seattle
    Thanks man!

    I'd make them, not sure what shipping would cost, or what I could charge for them.
    What do you think?
    :)
     
  17. Roadwarrior

    Roadwarrior Titan Swapped / SAS'd Founding Member

    Messages:
    5,475
    Location:
    Probably in class..
    I would buy one, or buy your old one if you want to try a new style

    Sent from somewhere by something
     
  18. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    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.
     
  19. AZhiAZiAM

    AZhiAZiAM Suspension Lift

    Messages:
    4,914
    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.
     
  20. Timrich

    Timrich Super Duper Moderator Lifetime Member Founding Member

    Messages:
    2,429
    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
     
  21. mudchet

    mudchet Got Mud?<br><img src="http://i164.photobucket.com/ Lifetime Member

    Messages:
    639
    Location:
    Brentwood, TN
    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?
     
  22. 02Xterra

    02Xterra Wheeling

    Messages:
    487
    Location:
    Central VA
    ^^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!
     
  23. Ghettomedic

    Ghettomedic Test Drive

    Messages:
    19
    Location:
    Ashland, MA
  24. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    Location:
    Seattle
  25. AZhiAZiAM

    AZhiAZiAM Suspension Lift

    Messages:
    4,914
    Location:
    Fresno,CA
    started this today got a little progress. thanks for the plans sionnach.
     
  26. TKDx00

    TKDx00 Lockers Installed Lifetime Member Founding Member

    Messages:
    2,075
    Location:
    S.Subs of Chicago, IL.
    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.
     
    Last edited: May 6, 2013
  27. Sionnach

    Sionnach Bought an X Founding Member

    Messages:
    79
    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".
     
    Macland likes this.
  28. TKDx00

    TKDx00 Lockers Installed Lifetime Member Founding Member

    Messages:
    2,075
    Location:
    S.Subs of Chicago, IL.
    Thanks...found several sizes... :)
     
  29. andrew38

    andrew38 Test Drive

    Messages:
    5
    Location:
    mckinney texas
    Very cool!!!! I am looking at doing something similar but a little taller to accomodate my toolbox. Great pix. thx.
     
  30. Stalin Calderon Ramirez

    Stalin Calderon Ramirez Test Drive

    Messages:
    1
    Anyone still have the PDF file of the blueprints? Dropbox link doesn't work anymore.
     

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