The DECKED drawer system is a modular storage solution designed for cargo vans and pickup trucks, offering users an organized and efficient way to manage tools, equipment, and gear. This article provides a step-by-step guide to installing the system, based on the manufacturer’s instructions and best practices. It includes hardware details, assembly procedures, and safety considerations to ensure a successful and durable installation.
Overview of the DECKED Drawer System
The DECKED system includes two large deck halves (one for the driver side and one for the passenger side), a center vertical panel, drawers, ammo cans (front and rear), C-channel components, and various hardware and accessories. The system is designed to be installed in a wide range of van models, including the Dodge Ram Promaster 136" wheelbase (2014–current). A complete installation involves shimming the load floor, securing anchor points, assembling the base structure, attaching drawers and shelving, and ensuring all components are properly aligned and secured.
Tools and Components Required
Before beginning the installation, users should gather the following tools:
- 3/8" socket
- 7/16" socket
- 7/32" hex wrench
- 1/8" hex wrench
- Wire cutters
The DECKED drawer system includes a comprehensive set of components, such as:
- LEFT/DRIVER DECK HALF – 1
- RIGHT/PASSENGER DECK HALF – 1
- CENTER VERT – 1
- DRAWER – 2
- FRONT AMMO CAN – 2
- REAR AMMO CAN – 2
- AMMO CAN LID – 4
- AMMO CAN WINDOW – 2
- C-CHANNEL – 2
- RULER – 1
- HARDWARE BOX – 1 (containing shims, weather strips, and various fasteners)
- SIDEBOARDS – 2
- BOTTLE OPENER – 1
- TORSION BRACE – 1
These components are typically shipped in a single box and are clearly labeled for ease of assembly.
Precautions and Safety Considerations
Before starting the installation, it is essential to review the manufacturer’s safety precautions. The DECKED system must be installed in conjunction with a bulkhead wall or adequate structural framework to prevent injury in the event of a traffic accident. Users are advised to follow the installation instructions precisely and avoid making modifications that could compromise the system’s integrity or functionality.
Installing the Drawer Handles
One of the first steps in the installation process is the assembly of the drawer handles. The handle requires the installation of springs, clevis pins, and hair pins. The springs must be placed into the cavities on either side of the handle slots, with the red spring designated for the right side. The spring arms should point inward, not outward, to ensure proper function.
Next, a clevis pin is inserted through each outside drawer hole and through the spring. The handle is then inserted behind the spring arms and rotated toward the clevis pins. Once aligned, the clevis pin is pushed through the handle hole and the inside drawer hole. A hair pin is installed through the clevis pin to secure it in place.
Users are advised to ensure that the long arm of the spring is horizontal and the short leg is vertical before inserting the handle. This step is critical for the smooth operation of the drawer and the longevity of the handle mechanism.
Shim Installation for Level Load Floor
Whether installing the system in a pickup or a van, the process begins with shimming the load floor. The double-stick plastic shims are used to ensure that the drawers sit level, allowing them to glide freely without binding. The placement of these shims can vary depending on the specific application and vehicle model.
Once the shims are in place, the system’s anchor points are installed. These anchor plates replace the factory tie-down loops in the cargo area of the van. In pickup trucks, the system may use the factory tie-down points or provide similar anchors. Users are advised to use hand tools for the installation but may choose to use power tools if necessary. When using power tools, it is recommended to keep them on a low setting and to be gentle to avoid damaging the components.
Assembling the Base Structure
With the shims and anchor points in place, the next step is to begin assembling the base structure of the DECKED system. A C-channel drawer guide is connected to the two corner ammo cans. The corner cans and the center rib are then placed into position, followed by the first half of the top deck. A second half of the top deck is then lowered into place and aligned with the first half.
Once all the pieces are aligned, a firm tap is used to fully seat the components. It is important to avoid drawing the pieces together with bolts, as this can cause misalignment or damage. The top deck serves as a stabilizing element by bolting to the center rib and the corner ammo cans.
The center rib is secured using nutserts in the plastic, and it is crucial not to overtighten these bolts to prevent damage to the plastic components. Four J-hooks are attached through the ammo cans to the anchor points, helping to hold the system in place within the vehicle. These are tightened in a crisscross pattern to ensure even distribution of tension and proper centering of the unit.
Installing the Drawers
After the base structure is in place, the drawers can be assembled. The first step in drawer assembly is the installation of the rear corner supports, which also serve as axles for the guide wheels. Once the corner supports and crossbar are in place, the wheels are slipped onto the axle and snugged in place.
The drawer assembly is then attached to the base structure, ensuring that the wheels align with the C-channel and that the drawers can glide smoothly. Users should follow the manufacturer’s instructions carefully to ensure that all drawer components are installed correctly and that the drawers operate without resistance.
Installing the Shelving and Support Components
For users who wish to add shelving to the DECKED system, the manufacturer provides detailed best practices for installation. The shelving must be bolted to the lateral steel tubes that run underneath the deck. These tubes are indicated by dimples on the surface of the deck and are co-molded laterally into the HDPE (high-density polyethylene) material.
It is important to avoid bolting or screwing shelving directly into the HDPE material, as this can compromise the structural integrity of the system. Additionally, users should avoid drilling into the C-channel, as this is where the drawer wheels roll. If shelving components need to be located on top of the C-channel, reference the manufacturer’s diagrams for proper placement.
When bolting to the lateral steel tubes, users should ensure that the bolts pass completely through the tube and are secured with a flange nut or nylon insert locknut. If the bolts are installed over the drawer cavity, they should be of sufficient length to not obstruct drawer function. Alternatively, the bolts can be installed from the underside after the holes have been drilled.
Mounting brackets are recommended for attaching shelving units to the deck. These brackets help to distribute the load and prevent the shelving from shifting or becoming dislodged during transport. Users should also distribute the mounting attachment load bars over large areas of the deck panel to provide additional support for the shelves.
Finalizing the Installation
Once the base structure and drawers are in place, the final step is to install the trim pieces. These include sideboards, a ruler with bolt size and unit conversion markings, and a bottle opener located in the lower concealment panel. These trim pieces not only enhance the appearance of the system but also add functional value.
Users who wish to add additional storage or organizational features can install tie-down anchors on the top of the deck using the manufacturer’s Core Trax rails. These rails bolt to the metal substructure and can support up to 500 pounds of weight. This feature is particularly useful for securing larger items or heavy equipment.
Another notable feature of the DECKED system is the inclusion of cupholders on the underside of the ammo can lids. These provide a convenient place to store beverages and other small items while using the van for work or travel.
Post-Installation Considerations
After the installation is complete, users should test the system by opening and closing the drawers to ensure smooth operation. It is also advisable to load the drawers with tools and equipment to verify that the system can support the intended weight without compromising functionality or stability.
Users should also be aware of the impact the DECKED system has on headroom in the cargo area. While the system does reduce available vertical space, the manufacturer notes that high-roof models, such as the Nissan NV3500, typically have enough clearance for most users to stand comfortably in the cargo hold.
Conclusion
The DECKED drawer system is a versatile and durable storage solution designed for cargo vans and pickup trucks. The installation process involves a series of precise steps, including the placement of shims, the assembly of the base structure, the installation of drawers, and the addition of shelving and trim components. By following the manufacturer’s instructions and best practices, users can ensure a successful and long-lasting installation that enhances the functionality and organization of their vehicle.
The system is designed to be user-friendly, with clearly labeled components and step-by-step instructions. However, it is important to approach the installation with care and attention to detail to avoid potential issues that could affect the performance or safety of the system.
For users who are new to vehicle storage systems or who are installing the DECKED system for the first time, it is recommended to have a helper on hand to assist with the more complex steps, such as aligning the top deck and securing the anchor points.
Ultimately, the DECKED system offers a high-quality solution for anyone looking to improve the organization and efficiency of their cargo space. With its modular design, durable construction, and thoughtful features, it is a valuable addition to any van or pickup truck.