Thread: D4 Rear Storage Project including drop fridge slide - Part 1

Here's a shot off the electrical connections. I need to get a grommet for the Cat5. The rubber hose is to prevent the plastic sides getting scratched when moving the shelf in and out of the car.



I bought some Hafele heavy duty drawer slides (225kg) for just over $100 on sale from the Internet and built the slide out of aluminium.





The hinge points on the slide have 608 bearings so that the aluminium doesn't get chewed up and it makes it very easy to lift and lower. The handle retracts so that it doesn't foul the rear door of the car.



I cut the slots for the retracting handle using a router with some kerosene to lubricate it - it took about 30min for each one. The piece that sits under the base of the slide (locking bar) in the photo above stops the fridge from dropping down. There is a simple lock with key on shock cord that prevents the fridge dropping until you are ready. The spare length of shock cord has a hook on it so when in the dropped position you can hook the fridge lid open.



I tested the slide with the fridge on and filled it with water (60L fridge). The slide had no problems handling the weight but it was a bit heavy to lift. I camping mode with beers and food for a week it was no problem lifting and lowering the fridge.

The only problem I have found was with the locking mechanism on the Hafele rails when locking in the closed position. The mechanism relies on the locking against the steel of the rail sides which is only a few millimetres thick. With the weight on the rails, they flex and the slide can open. I discovered this on the first trip to Moreton with it and the quick fix is the yellow Fasty strap you can see in the photos. I was thinking to make another locking mechanism however the Fasty strap is quick and convenient.

I built all of this with basic tools (cordless drill, reciprocating saw, router, mitre saw, rivet gun and soldering iron) in the small garage in my town house. It took around two weeks of very part time work back in December (Christmas parties and work kept getting in the way).

The system works really well with plastic tubs going in under the shelf and it has enough clearance to fit 30 can blocks of tinnies in there easily. The spaces between the shelf supports and sides fit the 40A DC/DC charger as well as providing good easily accessible spaces for snatch strap, compressor hose etc.

The only issue is access to the spare wheel winder but I have a plan for that. I just need to source some parts and once done I'll share that with you guys as well.

The next project will be a light weight camp kitchen that takes up the space beside the fridge.

If you have any questions or want to see some more photos, just let me know.

Dean

Good job on the slide, been looking at the drop downs but the cost is more than my fridge so DIY it will be.

Originally Posted by deano

Here's a shot off the electrical connections. I need to get a grommet for the Cat5. The rubber hose is to prevent the plastic sides getting scratched when moving the shelf in and out of the car.



I bought some Hafele heavy duty drawer slides (225kg) for just over $100 on sale from the Internet and built the slide out of aluminium.





The hinge points on the slide have 608 bearings so that the aluminium doesn't get chewed up and it makes it very easy to lift and lower. The handle retracts so that it doesn't foul the rear door of the car.



I cut the slots for the retracting handle using a router with some kerosene to lubricate it - it took about 30min for each one. The piece that sits under the base of the slide (locking bar) in the photo above stops the fridge from dropping down. There is a simple lock with key on shock cord that prevents the fridge dropping until you are ready. The spare length of shock cord has a hook on it so when in the dropped position you can hook the fridge lid open.



I tested the slide with the fridge on and filled it with water (60L fridge). The slide had no problems handling the weight but it was a bit heavy to lift. I camping mode with beers and food for a week it was no problem lifting and lowering the fridge.

The only problem I have found was with the locking mechanism on the Hafele rails when locking in the closed position. The mechanism relies on the locking against the steel of the rail sides which is only a few millimetres thick. With the weight on the rails, they flex and the slide can open. I discovered this on the first trip to Moreton with it and the quick fix is the yellow Fasty strap you can see in the photos. I was thinking to make another locking mechanism however the Fasty strap is quick and convenient.

I built all of this with basic tools (cordless drill, reciprocating saw, router, mitre saw, rivet gun and soldering iron) in the small garage in my town house. It took around two weeks of very part time work back in December (Christmas parties and work kept getting in the way).

The system works really well with plastic tubs going in under the shelf and it has enough clearance to fit 30 can blocks of tinnies in there easily. The spaces between the shelf supports and sides fit the 40A DC/DC charger as well as providing good easily accessible spaces for snatch strap, compressor hose etc.

The only issue is access to the spare wheel winder but I have a plan for that. I just need to source some parts and once done I'll share that with you guys as well.

The next project will be a light weight camp kitchen that takes up the space beside the fridge.

If you have any questions or want to see some more photos, just let me know.

Dean

Great work Deano. Do you know how much it weighs without the gear inside it?

Thanks

Shane

Originally Posted by plusnq

Great work Deano. Do you know how much it weighs without the gear inside it?

Thanks

Shane

Hi Shane,

the platform part without the fridge slide bolted onto it is about 12kg. The fride slide setup minus the steel drawer runners is about 3kg and the drawer runners are 10kg.

I'm nowhere near the biggest bloke in the world but I can lift it in and out of the back on my own OK - it's a bit awkward because of the shape and the weight is offset to one side.

The missus and I can lift the whole setup including the fridge into the back without too much problem - just drop the suspension so you don't have to lift as high.

Dean