Grizzly_Adams
10th March 2007, 04:25 PM
G'day all,
For a long time I've wanted to better utilize the space available in the back of the Defender. I've seen storage systems around and just wasn't satisfied with the exorbitant cost and sometimes even with the design.
So when I started at my new work and got to know people better, imagine my delight when one of the blokes there volunteered to help me design and build my own :)
The goal is 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.
So far we've only got the side storage pockets sorted but as we get further I hope to post more pics.
Step 1 was to get a suitable template for the sides of the side drawers.
https://www.aulro.com/afvb/images/imported/2007/03/221.jpg
https://www.aulro.com/afvb/images/imported/2007/03/222.jpg
https://www.aulro.com/afvb/images/imported/2007/03/223.jpg
A full size PDF of our template can be downloaded from my website here (http://www.bloodvale.com/temp/side-drawer-template.pdf) (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.
https://www.aulro.com/afvb/images/imported/2007/03/224.jpg
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.
https://www.aulro.com/afvb/images/imported/2007/03/225.jpg
https://www.aulro.com/afvb/images/imported/2007/03/226.jpg
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.
https://www.aulro.com/afvb/images/imported/2007/03/227.jpg
https://www.aulro.com/afvb/images/imported/2007/03/228.jpg
Step 5 was to put it in place :)
https://www.aulro.com/afvb/images/imported/2007/03/229.jpg
https://www.aulro.com/afvb/images/imported/2007/03/230.jpg
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 yet as it's a pretty rough looking paint job to say the least :angel:
At the moment the drawers aren't secured but they fit in snugly enough not to move about. Legally though I must secure them, and I will get around to that when we put the centre drawers in.
I've nipped down to bunnings and bought me some anti-slip under-pads to stop it from squeaking when I'm driving and help it not move about. First off-road trip with them in is tomorrow :) though I have travelled quite a bit with them on-road with no issues so far.
Many thanks to Vern Muddle from work (see picture above) for his great help and advice :) .. and before you think "this is too hard for me", both Vern and I are IT workers so hardly your most tradie-type people :D
For a long time I've wanted to better utilize the space available in the back of the Defender. I've seen storage systems around and just wasn't satisfied with the exorbitant cost and sometimes even with the design.
So when I started at my new work and got to know people better, imagine my delight when one of the blokes there volunteered to help me design and build my own :)
The goal is 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.
So far we've only got the side storage pockets sorted but as we get further I hope to post more pics.
Step 1 was to get a suitable template for the sides of the side drawers.
https://www.aulro.com/afvb/images/imported/2007/03/221.jpg
https://www.aulro.com/afvb/images/imported/2007/03/222.jpg
https://www.aulro.com/afvb/images/imported/2007/03/223.jpg
A full size PDF of our template can be downloaded from my website here (http://www.bloodvale.com/temp/side-drawer-template.pdf) (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.
https://www.aulro.com/afvb/images/imported/2007/03/224.jpg
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.
https://www.aulro.com/afvb/images/imported/2007/03/225.jpg
https://www.aulro.com/afvb/images/imported/2007/03/226.jpg
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.
https://www.aulro.com/afvb/images/imported/2007/03/227.jpg
https://www.aulro.com/afvb/images/imported/2007/03/228.jpg
Step 5 was to put it in place :)
https://www.aulro.com/afvb/images/imported/2007/03/229.jpg
https://www.aulro.com/afvb/images/imported/2007/03/230.jpg
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 yet as it's a pretty rough looking paint job to say the least :angel:
At the moment the drawers aren't secured but they fit in snugly enough not to move about. Legally though I must secure them, and I will get around to that when we put the centre drawers in.
I've nipped down to bunnings and bought me some anti-slip under-pads to stop it from squeaking when I'm driving and help it not move about. First off-road trip with them in is tomorrow :) though I have travelled quite a bit with them on-road with no issues so far.
Many thanks to Vern Muddle from work (see picture above) for his great help and advice :) .. and before you think "this is too hard for me", both Vern and I are IT workers so hardly your most tradie-type people :D