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Thread: Defender 110 Rear Storage

  1. #1
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    Defender 110 Rear Storage

    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.






    A full size PDF of our template can be downloaded from my website here (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.



    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.





    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.





    Step 5 was to put it in place





    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

    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
    Last edited by Grizzly_Adams; 10th March 2007 at 04:28 PM. Reason: Tidy up a bit

  2. #2
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    Dats Noice...... i love it... Well done...

  3. #3
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    excellent timing!

    and they look great!
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  4. #4
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    It's an art making use of the fenders "unusual" shape!

  5. #5
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    Alll very impressive,
    grizzly thats an interesting piece of 'machinery' one of those all in one woodworking devices, a pre-triton.

    keep up the good work


    john

  6. #6
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    You can relocate rear speakers inside these boxes, it'd be very good loud-speakers

    I had 'em here:



    Cheers,
    Ruslan

  7. #7
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    Wow I can't believe it's taken my almost a year to get back on to this project.

    Anyway originally we were planning on using a big wooden box in the middle of the back to house the drawers but after seeing Snappers drawers we changed our plans to use a metal framework with a single wooden drawer.

    At this stage I was thinking of scrapping the side boxes we'd made up...

    So we start out with some left over metal - dang it can't quite remember the sizings.. however it was something like 25 x 25 - not very big but plenty strong enough for the task at hand









    As you can see in this photo we used some wider metal (25 x 70?) for supporting the sides...



    Test fitting for sizing of the roof piece



    Almost completed framework



    Some tidying up




    Adding the securing plates

    A coat or two of paint





    Complete with drawers





    After fitting them I found I still needed more storage space. So I have resurrected the side-boxes and just need to give them a clean, another coat of paint and fit some tops before Cooma.. hopefully then will I have enough space for everything I carry in the back of the truck

  8. #8
    Bazz67 Guest
    Well done guys they look great and most likely save you a packet. more money for extras

    thanks
    Bazz

  9. #9
    numpty's Avatar
    numpty is offline TopicToaster Silver Subscriber
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    Good stuff Glen. Will have to park together at Cooma and compare fittings.
    Numpty

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  10. #10
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    Quote Originally Posted by numpty View Post
    Will have to park together at Cooma and compare fittings.

    Sure thing

    Oh and I got this information from my friend who helped make it:

    A few things.

    Metal is 25x25 RHS and 25x50 RHS. Both oversized, but what we had.
    Timber is 18mm 5 ply.

    Woodworking machine is cast iron 10inch tablesaw with router table extension.
    Sturdier but less portable than triton.
    We also used a jigsaw and a belt sander.

    Job could be done with jigsaw and hand saw for straight cuts.
    So you wouldn't need expensive equipment, just easier if you have it.
    The metal stuff could be done with timber as well.

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