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I made some drawers.

Discussion in '2nd Gen. Builds (2005-2015)' started by theREDwonder, Jan 21, 2018.

  1. Jan 21, 2018 at 11:30 PM
    #1
    theREDwonder

    theREDwonder [OP] Well-Known Member

    Joined:
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    Corey
    Huntington Beach
    Vehicle:
    2011 DCLB Sport 4x4
    Kings + Flippac
    The culmination of way too much time on the computer and in the shop. As is customary, finished photo first:

    GFQYhMrt6pCH2qbeV6ufLRW7Du-dMEf7iVxYcXoN_1cdf8821c517c94419a89b97e31e480d773bd053.jpg

    I wanted a way to keep stuff organized in the back of the camper. With the Flippac, stuff was floating around everywhere and it was always a mess after a single night camping (wife + 1.5 year old daughter). This will hopefully help keep all the camper gear underneath and the clothes relegated to duffle bags.

    I was inspired by this build, and even entertained the idea of buying it from him, now that it is for sale. I even looked at the decked system, but quickly balked at that after realizing that they are less than 45% efficient with the utilization of space. I have a friend with a full size truck and he loves them, they mid size truck iteration just wasn't doin it for me...and so I set off to design my own. I studied many builds, and thought about doing the ball bearing/tube sliders, but figured for the amount of money/time it would take to build, a set of drawer slides seems way easier/more robust. Using just wood seemed quick and dirty,
    but also heavy. My good friend had great luck with a fabricated metal frame + purchased drawer + purchased slides, and this was the best route I chose to follow.

    And so began the design:
    I wanted the frame to slide in between the wheel wells while maximizing width and minimizing dead space. I came up with the idea of "stacking" the two center slides, and this saved a solid 2" of dead space. I was apprehensive about doing this because EVERY single drawer I've ever seen/ googled has both slides on the same plane. The engineer in me said its fine, and it turned out great. I almost went with a single giant drawer that would be have been cheaper and lighter (only 1 set of slides, and less frame), but I figured I need the center support to serve as our floor in the flippac.

    Specs:
    Weight
    * frame: 54 pounds
    * 22.875" drawer: 32.3 pounds
    * 17.250" drawer: 27.5 pounds
    * 2x 48" 500 pound rated slides: 52 pounds total
    * Plywood Floor: 45 pounds
    * Mahogany Drawer Front: 5 pounds
    * Hardware: 6 pounds
    *Total: 221 pounds

    It came out heavier than I wanted, but there really isnt that many more places I could cut weight.

    Total money spent
    * Drawer Slides from Orr & Orr: $270 + $60 shipping
    * Drawers made by Drawer Box Specialities: $140 + $75 shipping
    * Plywood: $50
    * Mahogany: $20
    * Carpet: $20
    * Aluminum for frame: $175
    * Hardware: $45
    * Total: $855

    I could have saved a bunch by picking up the drawers, they were only 100 miles away, but by the time you factor in gas and time, the shipping was worth it.

    nLjVVgVRfA2Q46B3XxQ3qzMw9bcCZqUaZpNM9uPV_802893f191125cd11f187d81fdc50972a1b95269.jpg

    QcSj1w6ApD6OXzvV0Uwz3YTr4vazFCrxmJ49P0xk_8d6667b4ff4ea121e2235eea31ccc52da7a60e82.jpg

    x1F-iNnN3DbwxeVMNS0mwhUZVArtBz7g8IPEguXt_0276e37465e74fbd83eae428f547b33933f0b385.jpg

    Being an engineer is a blessing and a curse. I spent way to long measuring/building the Taco bed in CAD, but that ultimately led to a product that fit the first time.

    eJY-zpebsUf6nAjYzagVPWARipGHZ_VTfVC7EBRs_751eaa4e4599c749e4b6ca1fc51d80838bbba46e.jpg

    The drawers are 4' 6" long on 4' slides. This left an 18" full width cubby forward of the wheel wells. I plan to put a water tank in here.

    M48Jns6dio2gZvLNHmh8UDivVRDQ3Ryu19QUIAPZ_e589de67ba015da09bc1daa8b4d0f6f16ca080d6.jpg

    I fabbed the frame at work during lunch over a few weeks, having all the right tools sure makes it go that much quicker and easier.

    ngHRINTLuUsl0rpPNqrZ8QQKm72SaFNB3MY9Wd5k_531b4eba0080a4be1a83a40196d92a92b9adf3f5.jpg

    hT3pH94nUmnU2WzxILIWkRS33TfyNSeVFOppjaFj_7856c26e91da5eab78bd1b50798c77800e3aa7aa.jpg

    NbH5_zS_CRLooXcFMitPOzgbDJqOOOyfj0Prr_Yw_c25e875ce5e5c0d131e4c4387d2d9a93452e1736.jpg

    To keep the center "S" light, I used .125" wall C-Channel with a .25" welded in doubler. I then drilled the holes and installed stainless steel threaded inserts with a zinc chromate primer for corrosion prevention. The threaded insert install only took about 20 minutes, but not having to worry about aluminum threads galling or cross threading is worth the time.

    TCttmoV_urvyBZGDMc-Vew-XDylRT2BqohNaOm8u_6507860d791046d8667680e94cbdfebf2bd44ab2.jpg

    Test fitting the frame before it was fully welded, it fit! Thanks CAD!

    -pfiOhc_Pn8U4oExUNfg7Cd5KMwrgqOGol0tK8kS_494c62f685e73ad0976f951cfe90282f815cf996.jpg

    I_oaIS_usAYz60Nba8g00ASoPneC6k-nLzRGmMSr_89b7047707d70761a7966532aa0c32d3500e1341.jpg

    One detail I really wanted to get right was the drawer fronts. A single piece of mahagony was used for the drawer fronts/ trim. You can see the grain continue all the way through There were no second chances with the cuts on this piece.

    Ni9AFpfR1FDEFP_FeghC2MileyvDZalu4klTRSIQ_919922eba85412542fd0a2956ca26d04ce2a0ad7.jpg
    ZDQ7HqcF1xWeYvyCb4nIKtdDdxQ7CNRTAJa46TlJ_47e9cb353d657fcd89ed56db26f54dc994eaed2a.jpg

    Consulting the oracle
    pcCniIFYzdORh91MesFlaIwu0Xm9bGMqaHo3RyDo_f0e384fe8cb37327fc87fe0c112a0c56945f5cc6.jpg

    I made the floor piece out of some 3/4" birch ply. I would have gone lighter, but this will be the floor that we stand on in the camper, and I wanted it stout. The OCD in me is sad the carpet doesn't match the bed rug.

    rcdL8RiA8UCTNaZwtt6k6INMXIGzdx3iIg_7b-0M_7cf690a2ebb56f8c8639bd584c07da3261dfa113.jpg

    I cut the slots in both the drawers and the hardwood fronts, then fed the 1" webbing through and secured it on the inside. I choose webbing because I like to climb, and it seemed cool, durable, and cheap.

    B0ix4MqPp-9dSdsU7i1A8sk5IPXO8CVAO_8Yf7wa_67572833d5374a3d467ee34da106135ef7a79abd.jpg

    The little side cubbies are still accessible. I am going to carpet the little plywood covers. I have my power panel in the drivers side cubby so I wanted to still be able to get to that with the tailgate up.

    6mlG-kibfj6Oc4S8rBWnJPib9RyKw8gZDiYH4pbL_f5d2a1863027fd0613a279bdff6fb2eb1675cc17.jpg

    dC4JznnKX5QzXjiIMOijsQuyv0VicY_lZWYKospV_677840f2023bdc176a816e3658ca8f98deafda41.jpg

    The finished product. I'm pretty happy with how well it turned out. It's not perfect, but it should get the job done.

    dH88eGTiD4AlkK_X1NWdscIK8xQCEBFnsj7jF9MW_2fbc6508c41bb3c1b2ffac0f17e9524938ed54d0.jpg
    cr0G2WPvg5FDm62axKTqIw9N7jNiDnT5rzhpG0lH_769c245b016f8f5d7003bc58019c9550157249c3.jpg
    4WgAhFB1f3FR8XwKMymAjCyHT8U0aAJFTABfUyBN_3cb2562b8ca832f25f74739dad4fb2b04c92147d.jpg
    pom1KZzjkpjwZoCuu45cjT0n7pOvyErqzarNOSPz_66f5a4ca514456243db3b888d389e8e8e0539d32.jpg
    dsj1_U4dQ_5FZ--W9b2ahz-t9Nd6-DXpr8cGtKnq_92da63b53d1f94e52d30f0337690516ef65efdb5.jpg
    c7vyaQcP4bSunKXBBN9XCI-MaG4iABsg8K7TOcBJ_fb9d574d7616694ef7cb1cbc57b589c986d8770d.jpg
    VEvsBIlGkDsikXF2ke-3ZXVQjRo7bunDad9NaGBV_42dcb04ab424ad8d162572f0caf5bdaaed5ab891.jpg
     
  2. Jan 22, 2018 at 12:55 AM
    #2
    MarX

    MarX FAT-lete in training

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    Funky town
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    RETRAX bed cover, Tailgate lock, TRD exhaust. 887's, LR UCA'S, Bilstein 5100's and Deavers AAL.
    Wow that is awesome, nice work!
     
  3. Jan 22, 2018 at 5:07 AM
    #3
    dziner

    dziner Well-Known Member

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    Harrisburg, Pennsylvania
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    Bilstein 5100 (front) | OME 885 springs | Bilstein 5160 (rear) | OME Dakar medium leafpack | JBA UCA | Cooper S/T Maxx 265/75 R16 | ARE Z-Series topper | Renogy 100W solar panel | SnoMaster TR42 fridge | sleeping platform | Mobtown sliders | Custom Car Grills grill insert
    Awesome job on that! Is that a Habitat camper?
     
  4. Jan 22, 2018 at 6:53 AM
    #4
    theREDwonder

    theREDwonder [OP] Well-Known Member

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    Corey
    Huntington Beach
    Vehicle:
    2011 DCLB Sport 4x4
    Kings + Flippac
    Thanks guys. It is a Flippac, folds forward. The habitat folds backwards.
     
    MarX and dziner like this.
  5. Jan 22, 2018 at 1:26 PM
    #5
    TVRPhoto

    TVRPhoto Well-Known Member

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  6. Jan 22, 2018 at 1:39 PM
    #6
    theREDwonder

    theREDwonder [OP] Well-Known Member

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    Awesome, thanks for the info. That looks like it should fit well. I'm a little apprehensive about that much weight in water (170 pounds of water + 30-40 pounds of tank/ hardware!), but can also see the benefit of having it. My truck is sitting pretty good right now on the Dakar leafs. They are meant for 600 pounds of constant weight, and I'm right there (350 flippac + 220 drawers = 570 #). Once we toss in the camping gear, I'll probably be at the limit of usability before hitting the bumps regularly and without adding another leaf.
     
  7. Jan 25, 2018 at 3:39 PM
    #7
    Chepo

    Chepo Tankoma!

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    Lots...
    Woooowwww! that's a great project!!!
     
    theREDwonder [OP] likes this.
  8. Mar 12, 2018 at 11:31 AM
    #8
    upTOPOverland_Drew

    upTOPOverland_Drew upTOP Overland Technical Design and Application

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    All the things...click the link in sig
    holy moly this is awesome! makes me embarassed about my system.
     
    theREDwonder [OP] likes this.
  9. Mar 12, 2018 at 12:27 PM
    #9
    upTOPOverland_Drew

    upTOPOverland_Drew upTOP Overland Technical Design and Application

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    All the things...click the link in sig
    so did you use a combo of a locking slide and non-locking slide? has it held up well?

    I am getting slides from ryadon that has locking mechanisms on both slides, looks like ORR and ORR distributes these. i already have a set of non lockers. i was thinking of using one side of the locking slide and pairing it with the opposite side of my non lockers so i could effectively have two locking slides? what are your thoughts? looking for that engineering advice :thumbsup:
     
  10. Mar 12, 2018 at 2:24 PM
    #10
    theREDwonder

    theREDwonder [OP] Well-Known Member

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    Kings + Flippac
    That is exactly what I did. It seemed like over kill and extra money to have locking slides on both sides. You can see the blue locking tabs on the outside slides for each drawer (not on the inside). The slides are identical locking or not. The locking one just holds it open at full extension.
     
  11. Mar 12, 2018 at 2:34 PM
    #11
    upTOPOverland_Drew

    upTOPOverland_Drew upTOP Overland Technical Design and Application

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    All the things...click the link in sig
    Do you think the lock is stout enough to hold a fully loaded 65 qt cooler (~100-150 lbs) at full extension on a slight incline (that would cause it to close with gravity)? obviously its a static load and i won't be parking it on anything too steep as it need to be convenient for me too.
     
  12. Mar 12, 2018 at 2:37 PM
    #12
    theREDwonder

    theREDwonder [OP] Well-Known Member

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    The lock has a physical tab that clicks into place when it is open/locked out. I've definitely had 100 pounds in a drawer and it worked fine.
     
    upTOPOverland_Drew likes this.
  13. Mar 12, 2018 at 2:39 PM
    #13
    upTOPOverland_Drew

    upTOPOverland_Drew upTOP Overland Technical Design and Application

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    thanks, I figure this is what I'll do too as it just seems to make a lot of sense. My slides should be in late this week!
     
  14. Jun 3, 2018 at 12:29 PM
    #14
    zach101

    zach101 Mr.Ph1lip

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    Very impressive. I love the webbing handles with the mahogany
     
    theREDwonder [OP] likes this.
  15. Oct 23, 2018 at 1:08 PM
    #15
    azerathis

    azerathis Well-Known Member

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    Nice looking drawers. I like how you did the offset hinges
     
    theREDwonder [OP] likes this.
  16. Feb 4, 2019 at 9:50 PM
    #16
    theREDwonder

    theREDwonder [OP] Well-Known Member

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  17. Mar 23, 2019 at 6:48 AM
    #17
    Ccimages

    Ccimages Member

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    Great work. I'm near fountain valley and interested. I.M. your number to set a meet up. Thanks
     
  18. Nov 22, 2019 at 12:27 PM
    #18
    sachou

    sachou Well-Known Member

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    This is a work of art. I hope you got enough usage out of it to make the R&D time you spent to build it!
     
  19. Nov 22, 2019 at 2:50 PM
    #19
    theREDwonder

    theREDwonder [OP] Well-Known Member

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    Kings + Flippac
    I know its cliche, but the journey is the destination for me. I'm just as happy building them as I am using them. I definitely got my use out of them.
     

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