Thread: Puma Drawer Storage - DIY

Inspired by both the price of new drawer systems and the various threads on this site relating to peoples' own marvellous creations, I decided to give this drawer fabrication a crack.

The design:
I wanted a drawer and a decent-sized space to the side of it for my shovel, camping tripod, tent poles, fishing rods (in tubes) and anything else long. I'd already cut a section of my cargo barrier out to allow really long things to slide right under the rear seats so this channel was going to be on the driver's side.

I used the Qubelock aluminium square section (25mm) and the connectors to create a frame and inserted some 18mm exterior ply into the 'gaps' to give it all strength and then created a drawer to slide into the space. The frame was measured just high enough so that the top boards would span the entire cargo bay.

I got some 850mm sliders, rated to 100kg, from eBay and attached them using bolts to the ply , then to the drawer. To my amazement it all went very smoothly.

For the drawer and the top boards, I had a shocking time trying to keep the marine carpet tidy at the corners so I decided to cut it square and then edge all 3 pieces with aluminium L-section (25 x 20 x 1.6) which took ages but looks excellent - the laborious bit was cutting all the 45-degree sections with a circular saw and drilling and countersinking all the holes.

Once installed, I checked all the tolerances and measurements and found that Land Rovers aren't straight (of course my cutting was perfect ) so I used a little more foam protector under one corner than the others.

Final job I got around to was installing the tie-down points which I picked up from Opposite Lock.

I've never undertaken anything like this before so there was a fair bit of trial and error but nothing that was overly difficult. In hindsight this would have been so much easier with a drop saw and a drill press but I had a lot of fun regardless.

Jobs still to do:
- Attach a preventer to stop the drawer from sliding out when parked on a slope
- Clean up the aluminium and remove the barcode stickers
- Fill the drawer!

Thanks to Bunnings and Mister Ply for the materials and to Whitworths for the carpet and the horn cleat drawer handle.

I've written up a list of all the materials, tools and individual steps which I'd be happy to email to anyone who's interested so please PM me if you're keen.


Bobby



Building the drawer - steel corner supports going in


Steel L-section supports along the lengths and ends



Gluing the marine carpet to the drawer interior and wedging it with locally available materials


Initial installation - checking everything fits and adjusting accordingly


Channel lid attached with 2 hinges at the back

Looks fantastic a job well done!