Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
DIY Drawer System for Discovery 3
Been preparing for next trip in our Disco and just found out that there was too many things we needed to to collect so started to think of a drawer system.
What you can get on the market is ridiculously expensive Would build at least 5 such systems myself in that price, so decided to go for it
The first idea was to use alu square profiles and make kind of a construction with telescopic slides inside, but seems like finding longer ones than 700mm it's almost impossible. Well - you CAN get longer ones, but the prices are going logarithmically up, so resigned from that idea. Will use simple bearings and aluminium profile sliding between them.
Instead of alu frame, decided to build aluminium box.
Didn't want to build it too high, as we are travelling with our Husky dog, sitting in the booth, so had to think of saving some space for her (especially that she's been having only half of it - there are our Peli cases on the other half) So the whole box shouldn't be higher than 30cm.
Thought of using cable trays to build the outside box and drawers, but found it quite cheap to go to the company that deals with aluminium and let them do everything based on my project.
Labour and material (2mm aluminim plates on sides and 3mm on bottom) were around 100 Quids
Bought used booth floors from Discovery 3 on polish flebay - 2 sets. Will use those without handle as top of the drawer system, and will cut those with handles to build front of the drawers and make remaining pieces of the floor with the rests of it. Cost around 70 Quid for 4 pieces.
Can't wait to come back and continue on that one. .
I know drilling can be challenging - to make everything perfectly in line, especially at home environment, but expect to have fun with it, so looking forward
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
29th May 2015 7:59 pm
Blacknsilver3
Member Since: 21 May 2012
Location: Conwy North Wales
Posts: 441
What happens when you get a puncture? has that been thought of? Can you leave a hole out so it doesn't have to all be removed?With a few Mods.
29th May 2015 8:27 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
I have already removed the spare wheel from it's original position. Bumper mount is another DIY project I plan to do
BUT - if you slide the drawers to the very front and remove the upper floor (first part of it - in fact - top of the drawer system) you can see what's under the box. I don't want to make a full floor under because I have a lot of ropes, tools and other pieces of necessary equipment in the space where tool box used to be Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
29th May 2015 8:37 pm
~Rich~
Member Since: 16 Mar 2009
Location: Sydney
Posts: 627
Beware!
The floor of the rear in not flat and in line with the tailgate.
You need to pack up the rear of the drawers to clear the tailgate when you slide them out.
Check out my plans in my signature for details.
Cheers Rich2005 TDV6 HSE Silver, LLAMS Height Controller, Tinted Glass, Onroad - 19" GG AT's, Offroad - 18" 275/65 MT, Traxside Dual Battery kit, Rasta Protection Plate, Alpine Roof, BAS Remap, ARB Air Compressor, eDiff Custom Drawer and storage unit -http://www.box.com/s/jem0ilac3cner2mexq64 UHF CB, 4x4 Intellegence RWC, 120ltr Long range tank, Rock Sliders and Compressor protection plate Beanie grill, De Tango.
30th May 2015 10:40 am
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
Excellent guide you've put together there Rich
30th May 2015 11:17 am
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Thanks Rich
Interesting read
I am going to mount the box on a 20mm aluminium profile that will be screwed in to the original mounting points on the back. That should be enough for the drawers to slide completely out.
Also - using the sliding option consisting of bearings and aluminium profile should protect me from lowering the front of the drawers when they are completely out. Haven't checked it in the reality yet, but seems that should work
What is the total weight of your unit? Seem quite heavy, but I may be wrong Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
30th May 2015 11:19 am
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
First day of real work on the project
Aluminium rivets used to mount the floor with the sides of the drawer and two parts of the frame together.
Than measured the side of the frame. It's 255mm so decided to keep the middle of the sliding system 130mm from the bottom.
As the bearing is 22mm in diameter, and the aluminium profile is 50mm x 20mm, the middle point of the lower row of bearings will be 94mm from the bottom.
Guiding holes made with 2mm drill.
In fact - this is the most difficult part. To keep everything in line and made the holes precisely enough so it fits together and all bearings are holding weight. I had to re-do two holes as the drill slid a little
But luckily everything ended good
Before drilling in aluminium I made a sample on wood plate - to see if those bearings that are in fact holding most of the weight when the drawer is slid out will work ok. The distance of the first bearing from the front of the frame is 20mm, and the distance to the second one is 140mm. The others are 300mm from each other. Such concept works perfect.
After drilling in aluminium and putting the profile between the bearings it seems like the end of it, when it's slid out drops just around 5mm. So it fits pretty well.
Will work tomorrow on the other sides and hope to see the raw construction working in the evening Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
31st May 2015 10:27 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
Getting closer to the final product
Drawers are a little too tight in the frame. Should have left more room there.
Will have to re-design the sliders, but general idea was OK so keep going
Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
3rd Jun 2015 9:49 pm
tayaste
Member Since: 15 May 2013
Location: Chester
Posts: 7633
You've got my respect managing to get swmbo to help
3rd Jun 2015 9:51 pm
Simon.pl
Member Since: 02 Dec 2010
Location: Warsaw
Posts: 224
I don't really have to force her 8) I would rather say it's hard to get rid of Especially when something goes wrong and there is constant "question flow" - if you know what I mean But to be perfectly honest - it's fun doing it together! Wrapped Satin Yellow&Black; Lovells 2" Gas Legend Kit, OME hard springs. ATX 192 17" wheels with Cooper STT M/T tires. ProSpeed Roof Rack & Rear Ladder. Custom made underbody protection, front bumper, rock sliders, spare wheel and accessories mountings, drawer system. WARN 9,5XP Winch. Front and Rear Light Guards, Safari Snorkel. VIAIR X'treme Duty OBA, Traxide USI-160 system, Danhag GSM & IPCU modules, IID Tool BT, James Baroud roof tent and awnings, and air horn for fun
3rd Jun 2015 10:01 pm
Shepherd
Member Since: 06 Feb 2013
Location: Dundee
Posts: 12
love to have facilities like that Newbie to disco have just acquired one(wanted one for years)
Disco 3 TDV6 base model
Zermatt silver
3rd Jun 2015 10:55 pm
Iguana
Member Since: 14 Oct 2013
Location: 'Sunny' Zomerset
Posts: 9402
Cracking work so far and great to see SWMBO employed Iggy/Ieuan
Current LR =
2015 RR Sport Autobiography
&
1992 Land Rover Defender Camper
- Gone but not forgotten:
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MY05 Disco 3 'S'
MY14 FL2 HSE manual in Blue
MY15 Disco 4 HSE Lux in Santorini Black
MY08 Disco 3 SE manual in Buck Blue
1960 Series 2 88" (No idea why I sold it!)
3rd Jun 2015 11:02 pm
Magnet6x6
Member Since: 09 Dec 2009
Location: Al Hamra, Oman
Posts: 165
Looks terrific
How many mm is the ali you're using?
Edit:
Sorry just reread and found it If we weren't supposed to eat meat why did God make animals taste so good?
Prospeed XRS, traxide, Mitch Hitch, life is good.
4th Jun 2015 11:02 am
xcentric
Member Since: 01 Apr 2015
Location: Shropshire, UK
Posts: 1081
are the horizontal sliders bought in? been looking for some - where did you source yours?
4th Jun 2015 11:48 am
euangibson
Member Since: 24 Dec 2010
Location: Borders
Posts: 11027
Nice work....don't forget the foam padding for the bottles of whisky "Better to remain silent and be thought a fool,than to speak out and remove all doubt" ?.....what rubbish...
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Would build at least 5 such systems myself in that price, so decided to go for it 
So the whole box shouldn't be higher than 30cm.
has that been thought of? Can you leave a hole out so it doesn't have to all be removed?
But to be perfectly honest - it's fun doing it together! 
