First steps were to remove the existing tie-down points, rear seat mounts and seat belts.
I then made cardboard templates of all cut-outs and one of the floor pan to enable the use of existing captive nuts of the child restraints and seat mounting brackets in the centre of the floor.
I used 2 x 40mm 1/4" bolts and 2 x 70mm (10mm Metric, Fine) bolts and washers to secure the draws to the floor. For the two larger bolts I made two spacers out of 20mm square tube, cut to floor height (approximately 45mm) (See photos)
MATERIALS USED
1 off Sheet 2400 x 1200 x 18mm Melamine
3 off Rolls (2 x 1 metre) grey speaker carpet
6 off Recessed 'Trapdoor' handles
Roofing Screws & Lock nuts (For handles & tie-downs)
2 x 400ml tins "Gel Grip" (for carpet)
6 metres of 24mm x 12mm aluminium angle
Piano hinge
Screws, wood glue, 18mm brads, 12mm staples
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Construction was not difficult, but time consuming due to the intricacies of the various cut-outs, mouldings and storage pockets.
The reasoning behind the "Melamine" base and drawer bases, was for ease of sliding the drawers when fully loaded. This works and with some soap rubbed on the drawer bases it is even easier.
Apart from the base, drawer bases and ends, the rest was constructed from 12mm ply. I only used the Melamine in the drawer ends because I had enough left over and I felt it would give more stability. Everything was glued and screwed for strength.
I intentionally paced myself and was determined not to rush the job so that everything was thought of before completion.
This became evident in the very early stages when I cut out the base in one piece and finally had it fitting very neat. This was all very well when it was a flat sheet, but when constructed it was going to be another story, so I decided to cut the sheet in half and build as two separate sections, plus the side pockets.
This proved to be a very wise move as it would have been impossible to fit in one piece. To remove the unit it has to come out in the reverse order it went in, as it basically locks into place.
Since fitting, the vehicle seems to be quieter, and certainly no rattles from the drawers.
With the rear seat backs folded down and the bed extension in place it gives far more usable carrying space in the rear.
As we normally travel with the dog and canary on the rear seats, the bed extension had to be able to be stored for traveling and so it sits behind the rear seats.
The idea behind the drawer system was to allow us to camp in areas that were not assessable with the caravan. It had to be designed so that everything we needed to camp was also with us in the caravan and could be transferred to the Patrol, such as tarps, poles, ropes, cooking facilities etc.
We purchased a 4x4 self inflating camp mat which fits neatly in the rear of the car with the bed extension in place (1375mm wide x 1950mm long). The mattress when rolled up sits on the floor behind the seats.
A tarp (18' x 12') is attached to the roof bars, covering the rear half of the vehicle and gives a covered area at the rear for cooking & eating.
The Waeco fridge is taken out of the vehicle when not travelling.
Below is a link to a photo album of work in progress and the finished project.
http://picasaweb.google.com.au/CruisinTwo/DIYGUPatrolDrawerSystemBedExtension?feat=directlink
