Ultimate Truck Bed A do-it-yourself project from DIY Network's series Wasted Spaces: Karl Champley helps a contractor divide his truck bed in half horizontally, then build huge, pull-out drawers for all his gear.

(Continued from Page 1)

Karl and Matt build the shell and drawers for the storage unit, as well as wing boxes for additional storage. The assemble some small drawers to handle small items, then paint the entire system. Building the Truck Box The truck box goes together with glue and screws; use glue and nails for the wing boxes. The truck box will feature long drawers separated and supported by vertical dividers, flanked by "wing boxes" with smaller drawers. Use a table saw to rip one sheet of plywood to the dimensions for the vertical dividers from the design sketch. Safety Alert: Always wear eye protection and use caution when working with a power saw or any other power tool. Cut sheet of plywood to the dimensions for the top and bottom of the box. Lay out one sheet, carefully measure and snap chalk lines as guides for the vertical supports. The dividers should be spaced apart by the width of the drawers plus 1/2 inch. Line each vertical divider up with the chalk lines and attach using wood glue and 2-1/2" drywall screws. When all four dividers are attached, lay out the structure so the dividers are sticking up. Carefully position another sheet of plywood on top of the dividers and secure in place with 2-1/2" drywall screws. This creates the channels that will hold the drawers. Building the Drawers Again referring to the scale drawing, rip more plywood strips to form the bottom, sides and ends of the drawers. Also cut pieces of plywood to serve as dividers for the drawers. Note: Karl and Matt cut the front end pieces slightly shorter so he could simply grab the drawer front to open. Assemble the drawers with wood glue and 2-1/2" drywall screws. Start by attaching the sides to the bottom, then attach the ends. Once the outside of each drawer is built, use glue and screws to attach the divider pieces. Use wood glue and nails to attach thin pieces of wood trim to the bottom of the drawers. This trim will lift the drawers up slightly and decrease friction between the drawers and the box, making the drawers slide more easily. The wing boxes will slip into the small spaces by the main box, behind the wheel wells. Building Wing Boxes Use the table saw to rip smaller pieces of 1/2" plywood for the wing boxes that slip in next to the main truck box. Assemble the wing boxes with wood glue, using a nail gun to tack the plywood into place. Safety Alert: Always wear eye protection and use extreme caution when working with a nail gun. These powerful tools can drive a nail through wood – or a hand or foot – instantly. After the boxes are built, assemble the drawers using wood and nails. Slide the drawers into the wing boxes to check their fit. Painting the Unit Remove the drawers and use exterior-grade paint to paint the outer surfaces of the truck box and wing boxes. Also paint the drawers, inside and out. Do not paint the wood trim runners along the bottoms of the drawers. Choose a paint color that coordinates with the truck but also contrasts with the colors of the tools. This will make the tools easier to find in the drawers. Let the paint dry completely. PREVIOUS  1 | 2 | 3  NEXT