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Storage Drawer Build


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#1 Mark

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Posted 16 March 2008 - 09:47 PM

This seems to be a fairly popular topic at the moment, but it is something I have had in the back of my mind for some time. With some proposed travels coming up in the near-ish future, I thought I would finally get on with building some drawers to keep stuff in, for the discovery.

I have seen the MSS store drawer and a number of other solutions from both Australia and South Africa, but they all came out a little too pricey for my budget. Whilst my solution hasn't necessarily been the cheapest way to go, it certainly isn't into the realms of the commercially available systems.

My criteria for the drawers were as follows:

- Made out of metal - My disco leaks, and I have a habit of dunking it into damp places, so wood is not favored.
- Fit into my existing Load rails - see pics below
- Easily removabale from said load rails
- Not stop the Load rails from being used for other stuff...
- Be strong enough that I could put anything on top of the drawers that I might put in the boot of the truck
- Be able to carry recovery gear and tools, and whatever else I need reasonably instant access to...
- Be made by me, at home (mostly) with whatever materials I can obtain cheaply and easily...

The Back of the disco has load rails thus:
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I have since removed the rear dickie seats, the resultant gap will be used to hold jerry cans.

Layoutwise, the MSS design uss a single drawer, and a lcokers either side. The lockers still require you to unload whatever is on top to get to them, so I went for 2 drawers next to each other.

I decided to use a frame type construction, as I can fabricate that relatively easily. Folded construction is good, and often lighter, but requires the use of a folding machine of some description, whereas framework can be cut and joined quite simply. The trade off here is efficient use of space; a folded construction can utilise the space better, whereas the framework will intrinsically lose some space.

I came to the conclusion that the drawers and the outer frame would all be made from 20mm square ERW steel. This is quite a thin wall material, but gives good strength for this sort of application without being massively heavy. I went through using stainless or aluminium, but I an not setup to do either at home, so steel won! The Steel came from my friendly local blacksmith (thanks paul) and so far I have used nearly 18m of it :o that is 3 6m lengths!

Outer Frame Work:
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A Drawer Frame:
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The outer framework only needs to have the top covered - the sides are fairly immaterial at this stage. This will be done with 3mm aluminium, obtained from the scrap yard - an ex-road sign. The same piece of ally will yield the front/bottom piece for the draws themselves. This has been folded using a brake press, but is the only bit so far. The sides of the drawers will be filled in with 1.6mm ally, as that is what I had lying around (from previous visits to the scrap yard!)

The Drawer Front/Bottom Piece:
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How the drawer will fit together:
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The slides / runners for the drawers came from an equipment rack, also at the scrap yard, and are rated at 75kg per pair. I figured this would be enough for my use. They are 600mm long, but my drawers are 700mm deep, so I decided I would just put up with the 100mm difference.

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The drawers will be kept closed using the same type of catch as the MSS draws use - that is a Southco Paddle latch. These are physically huge, but if you need to get in the drawer whilst wearing gloves for example, then the size is good. I am using the non-locking stainless steel variety, since that is what I could get at a sensible price. Mine came from the states, since anyone in the Uk was looking at 40 per catch. With the shipping and a bit of duty, these came to just over 20 each - by far the most expensive single component in the build!

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I wasn't too worried about them not locking, as with the rear door closed, you will not be able to get to the front of the drawers anyway.

Have just about got the frames finished, and all the pices in place to get the drawers together. Framework needs the welds dressing back, since my design has some fairly close clearances, but my welding doesn't! The frame needs paint, and then the whole lot can be constructed....

watch this space....
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#2 Pete Attryde

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Posted 17 March 2008 - 08:24 AM

Good progress there, Mark.

I still haven't even started measuring up for mine. :lol:

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#3 TJ101

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Posted 17 March 2008 - 08:30 AM

Mark

These are surely going in the "new" disco :unsure:
Regards Tim
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#4 Mark

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Posted 17 March 2008 - 09:28 AM

Tim,

Yeah they are going in the new one now, but I started them before I got it! The new one will have the cargo rail in, the same as the old one though. Alternatly, I will make the drawers bolt down through the 4 threaded holes already present in the Disco floor... The design is still fairly fluid!

;)
Mark
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#5 iomlt

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Posted 17 March 2008 - 10:07 AM

:o thats going to weigh some!!!!! :o

#6 Mark

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Posted 17 March 2008 - 10:11 AM

Not as much as you might think. I can lift the total of what I have made so far with one arm... I will weigh it when it's done though...
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#7 Night Train

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Posted 17 March 2008 - 06:51 PM

Using 18mm birch ply and some hard wood battens would probably weigh more as you have material and strength where you don't always need it.

Nice job there Mark.

#8 Mo Murphy

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Posted 18 March 2008 - 06:49 PM

Mark, I've just hijacked your thread to show my drawer build too :) Since I'm making mine from wood it should make a nice contrast to yours whilst staying on topic :)
As far as design goes, I'm just making it up as I go along !

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Mo
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#9 Mark

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Posted 18 March 2008 - 08:53 PM

Mo, I like it. I thought about the shelf idea too, but the discovery has a rather large bumper that works very well as a table!

Is there more do go on top or down the side?
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#10 Mo Murphy

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Posted 18 March 2008 - 10:46 PM

I'm going to board straight across the top Mark but I'm not sure what to do with the bit at the side yet as I'm making it all up as I go along. My toolbox did fit in there but the build has crept across the back and there's not so much space now. We'll see, perhaps I'll have to invent a use for it. :) The front has yet to go on and I'm not sure about what latch to use yet. I've also got to put a divider or 2 in the drawer and then we'll be about done :) I hope...

Yours is looking very substantial, that's going to take heaps of abuse ! Looking forward to seeing the remainder of the building of it :)

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Let him that hath understanding count the number of the beast: for it is the number of a man; and his number is one hundred and ten

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#11 draper40

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Posted 19 March 2008 - 06:46 PM

Mo,
Where did you get those rails from?
Pete
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#12 Night Train

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Posted 19 March 2008 - 08:24 PM

Those drawer runners are available from B&Q in a range of lengths and can also be full extension so 600mm will pull out 600mm.

#13 draper40

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Posted 19 March 2008 - 08:34 PM

But they only seem to be rated to 45kgs-is this enough? Are they online as I can't seem to find them?
Just done first ever re-spray!

#14 Night Train

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Posted 19 March 2008 - 08:45 PM

B&Q have a crappy website (I hope you are reading this, B&Q) and it is next to impossible to find stuff there. It is easier to go to the store and look in the hardware aisle. Ebay has some.
45kg isn't too bad, near 100lb. If you need more capacity then you can double up on them, leave a 15mm gap between the sets to make it easier to install when you have removed the drawer though.

Found the B&Q page.

#15 Mo Murphy

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Posted 19 March 2008 - 09:13 PM

Yup, Mr. Night train is quite right, B&Q it was, 13.50 for the pair, which is very reasonable you'll find, if you care to shop about :)
Mo
Let him that hath understanding count the number of the beast: for it is the number of a man; and his number is one hundred and ten

The Land Rover 90: Many are called, few are chosen ...

#16 Night Train

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Posted 19 March 2008 - 09:25 PM

As a bespoke cabinet maker it pains me to say I do use B&Q drawer runners quite a lot both for my own work shop storage and for some of my clents who need or want full extension drawers.

#17 Mo Murphy

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Posted 19 March 2008 - 09:57 PM

Can I be one of those too now ? :)
Mo
Let him that hath understanding count the number of the beast: for it is the number of a man; and his number is one hundred and ten

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#18 Godlykepower

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Posted 19 March 2008 - 10:03 PM

Mark, that is looking pretty bloody good mate. I am watching this with interest! I cant wait to see the end result.

Mo.....damn, you started before me! I am begining mine tomorrow. Managed to get some Birch ply just down the road, and have been tweaking the design, so I think I'm about ready to start now. Do you have any more pictures at all??

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#19 Night Train

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Posted 19 March 2008 - 10:05 PM

Can I be one of those too now ? :)
Mo

If you like. I had to give up my job and study full time for two years and then sell my Harley and equip a workshop and then start making and finding clients. There's no money in it though so I teach it at college two days a week.

#20 freeagent

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Posted 19 March 2008 - 10:15 PM

I used to do that job, making posh furniture and nice fitted kitchens for people.
its hard work as nobody appreciates the work that goes into building something from scratch...
currently without a 4x4 as life is getting in the way!




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