Wood or metal frame for drawers

[bossman429]

I plan on building a pretty simple drawer system for my 100 series. I want two slide out drawers that go as deep as the back of the second row seats. Ill have a flip over platform to make a sleeping area when we go on trips and the 2nd row seats are out. Additionally under this space of the flip down portion we can store bags and boxes and stuff.

Now I'm rather handy and can weld steel as well as I can do carpentry. What are the advantages/disadvantages of both materials?

Should I make the frame out of steel but the drawers themselves out of wood? everything out of wood? everything out of steel? Wood will be quieter I assume but possibly a bit heavier (I'd use 1/2"-3/4" plywood, where as in steel I can use much thinner material and less of it)

I've seen both, the majority are wood, but I assume that's because most people don't have welders

 

[Woodsman]

You will find that even a well-engineered metal-framed unit will be just as heavy as all wood drawer units, unless you underbuild it.

Internal space really is not gained with metal construction as you either need a framework or turned down edges to give the panels rigidity.

You can use wood panels on a metal framework but again this can reduce the internal space available in the drawers due to a combination of the thickness of panels and thickness of framework.

 

[bossman429]

You will find that even a well-engineered metal-framed unit will be just as heavy as all wood drawer units, unless you underbuild it.

Internal space really is not gained with metal construction as you either need a framework or turned down edges to give the panels rigidity.

You can use wood panels on a metal framework but again this can reduce the internal space available in the drawers due to a combination of the thickness of panels and thickness of framework.

I was thinking if I used angle iron instead of tubes it may get rid of the extra thickness because the panels could fit neatly inside the seat the angle creates.... However I don't think I can find thin enough angle that would make it worth while, as thick angle would be heavier than thin tubing that gives the same rigidity and strength.

I also thought of a steel framework and riviting aluminum sheet metal on the sides and top in order to cut down on weight.... Again I don't know if this would be substantial savings or not, but it was a thought.

 

[Woodsman]

You got it. The angle themselves will be much thicker than just using a 3/4" panel.

Again, with a angle framework (or even that fancy aluminum extrusion stock) you will lose a bunch of internal space because of the thickness. The aluminum sheet will be light weight but I don't think the pounds saved will be worth it . . . plus you need something reasonably substantial on the sides for attaching the slides.

We can do great things with our storage but in the end there are always compromises between weight, storage efficiency and overall costs.

 

[MANUCHAO]

I build/welded a frame/cage out of metal with steel band 1"W x 1/16" or 1/8" thick...
It was some what flimsy at first but once I bolted down the HD sliders it was quite rigid...
I then build the drawers out of 5152 3/16" aluminum which does not require preheating to bend.
I had to find an aluminum welder dude to weld the ends of the drawers... but they came out really good
for the top I wanted to use aluminum again, but it is expensive so I went with 1" thick plywood coated with a Line X like product.
once the top got bolted down, it got the rigidity I was looking for.
I think plywood def be cheaper but you also need more expertise on working with it.. I dont have any experience or tools to work with plywood, this is why I went with metal.

I think using roller bearings would help substantially on the weight factor... on either plywood or metal drawer system..
My set up has held up great, but damn it is heavy...

If I was to do it again I would use aluminum all around and roller bearings instead of sliders...
My drawers are 42"L x 21"W x 9" to 10" H

 

[bossman429]

I think I have the design in my head.

I think I'm going to do a steel frame with tubing I have laying around, sheeth the sides in aluminum (riveted), but the drawers and top will be ply wood.


Here's my thinking. Steel welded frame can be minimal, doesn't take much to make it rigid and strong. Also I can basically have no bottom which will save weight. Just two pcs of real small tubing laying across the bottom to anchor it to the floor and to add a little rigidity. Also helps I have plenty of tubing sitting around

Aluminum sheet sides, again- weight savings over plywood and sheet steel, not structurally integral to the unit.

Plywood top and drawers. To help dampen sounds and provide a solid feel to everything. Will use 1/2 or 5/8 for the top piece, probably 1/2" for the drawers themselves. Will probably also cover in a carpet material to match the rest of the truck.


Not sure when the build is gonna start, but will post a thread on it for sure. Thanks for all the help guys

 

[4x4junkie]

Take a look at the setup I built for my BII, maybe you might be able to steal some ideas from it (or maybe not, sounds like you've already nailed it down pretty much like mine is lol).
http://www.expeditionportal.com/for...r-drawer-storage-system?p=1135873#post1135873

The whole thing (minus contents) is somewhere around 80lbs, which I find hard to believe you could get a similar design that light using an all plywood structure unless maybe you omitted the drawer slides (which would take away any possibility of having full extension capability on your drawers).
I've carried about 500lbs atop the unit up & down the west coast highways and thru the rugged washboarded 4x4 trails in Death Valley (among other trails) and it's held up great so far.

 

[Dennx]

What about using aluminum square tubing, sheets and nylon connectors?

[video]http://m.youtube.com/watch?v=GaYrMPE9Td0&desktop_uri=%2Fwatch%3Fv%3DGaYrMPE9Td0[/video]

Connectors
http://www.brunnerent.com/Tools/Portfolio/frontend/itemlist.asp?reset=1&type=2&lngDisplay=2