One of the most useful additions to our cali is the slide-out drawer fort he luggage compartment of the van. It allows you to make use of the space very efficiently and makes it easier to reach all your gear.

There are several different commercially sold drawers, ranging from 500 euros up to 700 euros or more. There are however, also quite some Cali owners who build one themselves. I did as well.

I started by creating a model in Sketchup. You’ll find the model here (compressed in a .zip file) in case you’d want to use it to copy my design.

The model, exact dimensions in mm, made in Sketchup…

The second step was ordering aluminium L-profiles. There are several online shops that will cut them to your desired dimensions and ship them to you. I ended up using www.aluminiumshop.nl.

Materials

Below you’ll find the list of profiles I ordered, in case you would want to build the drawer for yourself.:

Frame:

1x 80x40x5mm 1000mm long
2x 80x40x5mm 750mm long
1x Strip 40x5mm 1000mm long


Drawer:

2x 80x30x3 740mm long
2x 80x30x3 951mm long

Both the frame and the drawer are made out of L-profiles .

The entire construction is made up out of two parts:

  1. The ‘frame’, made of 3 aluminium L-profiles and a aluminium strip (5mm thick) , which are connected to the Cali’s floor rails with bolts.
  2. The drawer, made of 4 L-profiles (3mm thick) and a multiplex bottom plate (9mm thick). Both are joined together with pop nails/ rivets.
The frame (5mm) and the drawer (3mm). Joined together by pop rivets and drawer slides, which are connected to both the farme and the drawer with bolts.

The frame and drawer are connected to each other by using strong drawer slides, which I orderd from a German website: Teleskopschienen24.de. They can carry up to 130 KG. They turned out to be a very good quality drawer slides and the website’s service was good. There’s even a very clear instruction manual in PDF on their website and a very useful explainer video on Youtube.

The multiplex board is made of 9mm water resistent multiplex. I also added some cheap anti slip material that helps prevent things from sliding.

Cost

The aluminium (cut to size and delivered) cost 108,33 euros. De drawer slides cost 79 euros. De special bolts to attach the frame to the Cali rails cost 27 euros, but in hindsight they could have been any M8 T-shaped bolts. So you could save on cost. De board cost 32 euros, but I ended up using less then half of it. So there’s another opportunity to spare on costs. A couple of bolts, pop rivets. Al in all I spend less then 250 euros.