Low Profile Drawer Build

Any thoughts on this build for a low profile drawer box? I’ve been fabricating this box system which will be covered in 1/4” ABS, riveted to the steel frame. Two full extension wood drawers (Baltic wood) with dividers and compartments. The drawer system is designed for a drop in and turn buckle mounting system, and modular boxes can be clipped in to make different combinations. I’ve only seen one brand that has such a modular system. the system also is unique by leveraging side supports that create a storage area over the wheel wells and prevent gear from falling /rolling into the cargo area.

Additional modular accessories can be used like a bolt on security box/cage on top of the base drawers , this can allow storage of gear in a lock cage essentially.

gear tie downs, extension bars, platforms etc can all be modular.

 

Here’s an update with the ABS cut to fit and a dry fit on everything.

 

Installed both drawers.
Welded the drawer guides in. Seemed to work perfect.

 

Looks good, i built a low profile box as well. I love it. Probably one of the best mods.

 

That looks great. I like how you did the drawer fronts with the latch cut outs. I’ll probably borrow this method!

 

If i changed anything it would to put only one latch on each drawer.

 

I thought of that as well, but after it was all installed as takes away from having a handle on the front, and forcing the user to grab the sides which is difficult. The drawer rails came as a set, each having a latch. I suppose there are various drawer guides with one, two latch.

 

95% complete.
Just need drawer front cover, 1/8” sheeting on the sides (didn’t account for the ABS thickness on the width.

used 5/8 sq tube steel and 1/4” ABS with 5/8” x 3/16” rivets and glued with silicon.

I added structure plates on the corners to mount tie downs (bolt through)

the next piece will be a larger box that snaps in on one side. I could make an extension platform for a sleeper.
Working with that ABS is nice! Cuts like wood, sands smooth. Heat formable too with thinner sheets. I’ll probably carpet the inside drawers.

Full cost material
$115 ABS sheet 4x8
5/8” steel sq tube $40
$160 for drawer guides $80 x2
$180 Baltic birtch plywood
$20 rivets
$12 turn buckles


not bad for DIY pricing.

 

PCPRIDE4RUNNER, Could you post the drawer dimensions and the overall weight? Thanks

 

here are the details.


4runner low profile Drawer box


Frame outer dimensions (assumes the frame thickness is 5/8 x 5/8” steel sq tube)

41” width

33” 7/8 depth

7” height

Drawer cavity width 19” 5/8” (5/8” divider)


Drawer dimensions - used 5/8 and 3/8 Baltic birch plywood)

Dado the bottom of the drawer (3/8”)

Lap joint , glue and nail sides

Dado side cutouts for dividers if you plan that

32” 3/4” x 17 7/8 x 5” 3/8”

Drawer boxes assume 7/8” on each side to allow for drawer guides. Drawer guides will have different thicknesses so double check if you aren’t using the exact drawer guides here 32”


https://a.co/d/2W7Z52J

Rivets for ABS paneling

$19 QWORK Large Flange Blind Rivets, 500 Pcs Blind Rivet, 5/8" Flange Diameter, 3/16" x 5/8"

https://www.amazon.com/dp/B0C4TQ1X1B



Optional- The side top extensions for cargo is a 60 degree slope on the back to allow for the rear seats to recline fully w/out hitting the boxes. The height is 8”. The side extensions allow storage items above and around the wheel well without it falling/occupying the cargo area


If you plan to use these dimensions, and the ABS paneling, buy two sheets 1/4” and 1/8” . The 1/8” is used for the sides. Because this design doesn’t allow an extra 1/4” allowance for the ABS to fit between the plastic in the 4 runner. See picture. Otherwise reduce the overall frame dimensions by 3/8” to allow 1/4” ABS sheeting on each side.


Note: this exact design using metal sq tube and requires the top to be capped with alum channel if you want a finished look. (Still working on a solution. You could cap it off with the ABS and it wouldn’t look too bad after Sanding)
and welding keeps the weight down compared to larger plywood. Using the Baltic birch plywood dimensions stated above is on purpose as you don’t need a full 3/4” plywood. Estimated overall weight is 50-60lbs


Detail showing the tolerance if using 1/4” ABS sheets on each side.

 

Well done .

 

Nicely done and clean! Drawer slides jack the price up! I'm about the same cost as you and did mine out of all birch 2 years ago.

 

Adding mod box plus. Provides extra storage when traveling, while keeping gear organized and accessible. Bonus wheel steering wheel turny thing. You never knew you needed it until now.

 

Got it all done. Just need to cap the edge with alum angle.
Total cost at about $700 and about 5 days labor.

the larger box bolts down, you can see the access panel on the back (didn’t weld the plates in the right spot so I have this extension). Looks fine tho.

Welded the gear basket, then bolted to the box.

learned other ways it could be built, but that’s how the first one goes. I think it makes use of the space and all things in the cargo space fit neatly on the outside , like bags etc.

I might add a stop bar that goes across the front edge so stuff doesn’t slide out. Ideally an adjustable sliding/lock like a truck bed set up.




Fits the smaller Packout boxes perfectly.