|Almost complete, just needs the splash board installed and then secured to the floor.|
After a second set of drawings I set about deciding how to build the thing. Initially I planned on using 3/4" plywood but I don't have a lot of woodworking tools or skill, nor do we have much room to work with/store large material. As an amateur welder, I decided to take on build the frame out of 1" square steel tubing and intended to construct the drawers with pocket hole screws. I sketched out a plan, took some measurement and called an order into the local steel yard.
After a bit of rummaging around the internet I found a place in San Diego that will build sized to fit drawer boxes with full length sliders, so I chose to go that route to save myself some time. In hindsight, I should have just used the pocket screw joinery as it took over a month to get the drawers back which put me into he middle of the worst time of year for working outside. I have since built the box that sits underneath the flip top counter, where we will store the stove/utensils and what not, and it is really easy to make nice boxes using the Kreg brand joinery tools. Also, it requires you have only a circular saw, straight edge and a drill to build functional drawer boxes. Regardless the drawers are nicely constructed, though some of the edge laminate has come off already. They cost ~$150 plus shipping, which included the slide rails and hardware. Not too bad, but if you are on a tight budget you may want to stick with DIY.
As the fabrication progressed I bought some 90 degree corner jigs to help assemble the frame squarely. They have come in useful for the frame and building boxes with the pocket screw kit
In order to give myself a place to attach the side cabinet, and the future potential of adding a flip up auxiliary counter extension, I used a 1/2"ply, stained and urethaned to cover the side of the kitchen console. I used 4MM corrugated plastic, the kind they make signs out of, for the front side of the cabinet since it will essentially be unused and the material is very lightweight.
|The cooler slide in action|