These are material and design ideas from the original build notes. Check the finished weight, door clearances, edge protection and fastening plan before buying or cutting panels.
My Aluminum Enclosures and Removable Storage Baskets
I built aluminum-extrusion enclosures, lined them with thin panels and stapled carpet over the lining. Inside, I use removable storage baskets to organize my belongings. This is the storage approach I actually built after considering cabinet designs.
The Carpet and Lining I Used
The carpet came from Home Depot: the 6 ft. x 8 ft. Wide Wale Grey Rug. I used it over the thin panel lining on the aluminum enclosures. The fabric storage baskets came from Amazon.
Keeping the Baskets in Place While Driving
I keep the baskets inside the enclosures while driving with bungee cords and hooks at the ends of the cords. I drilled holes in the aluminum extrusion for the hooks to pass through and attach to.
Why I Am Replacing the Fabric Baskets
The 11-inch fabric baskets I used have fallen apart over time, especially when holding tools or heavier items. That has been the main weakness of this part of my storage setup.
I have now ordered Curver's grey 17L Jute Cube resin baskets to replace them. I am hoping these will hold up better, and that is what I will be looking for as I make the change.
Carpet and Basket Options
Used on my enclosures
Home Depot Wide Wale Grey Rug, 6 ft. x 8 ft.
This is the carpet I used over the panel lining on my aluminum storage enclosures. The Home Depot rug measures 6 by 8 feet before cutting.
View the Rug at Home Depot
Replacement I ordered
Curver 17L Jute Cube Resin Baskets
The grey Curver cubes have a woven-look resin body and carrying handles, and this listing supplies a four-pack. The listed dimensions are 10.75 x 10.75 x 10.63 inches.
View Curver Baskets on Amazon
Amazon carpet alternative 1
Purthog Cuttable Felt Carpet, 40 x 70 Inches
Purthog's listing describes this felt sheet as cuttable and suitable for fastening with staples. The 40 x 70-inch sheet is smaller than the 6 x 8-foot rug I used.
View the Felt Carpet on Amazon
Amazon basket alternative 1
Tstorage Collapsible Plastic Cubes, Four-Pack
These folding plastic cubes have cutout side handles and fold down for storage when empty. Their listed dimensions are 10.82 x 10.82 x 11.22 inches, making them taller than the Curver cubes I ordered.
View Tstorage Cubes on Amazon
Amazon carpet alternative 2
Audiopipe Black Enclosure Carpet, 36 x 48 Inches
This black synthetic carpet is listed for speaker boxes, door panels and enclosures. Its 36 x 48-inch piece is smaller than the 6 x 8-foot Home Depot rug I used.
View Audiopipe Carpet on Amazon
Amazon basket alternative 2
Ucake Foldable Plastic Cube Bins, Four-Pack
These grey plastic cube bins have side handles and fold down when empty. Their listed dimensions are 10.75 x 10.75 x 11.14 inches, making them taller than the Curver cubes I ordered.
View Ucake Cubes on AmazonCompare Cabinet Panels Before Choosing A Finish
Choose the panel for the cabinet part and its intended use, then compare the finished assembly. Keep the core, decorative surface, thickness and required hardware as separate comparison entries.
| Core | Compare These Details |
|---|---|
| MDF | Columbia Forest Products describes MDF as a wood-fiber-and-resin core with a smooth surface, denser and heavier than veneer core. Check the exact grade, finished part weight, edge treatment and hardware requirements. A smooth face alone does not answer the weight or attachment question. |
| Veneer Core | Columbia describes layers of wood veneer arranged in alternating crossbands. Identify the actual panel construction, thickness and product data. A “plywood” label alone does not specify every core or establish a suitable cabinet connection. |
| Veneer + MDF | Columbia's Classic Core combines veneer inner plies with thin MDF crossbands adjacent to the decorative faces. Confirm the complete product specification rather than assuming that a decorative face tells you what is inside. |
These descriptions come from Columbia's Core-Material FAQs. They help identify the construction being compared; they do not provide a tested van-cabinet design or a weight for the historical panel linked below.
Read The Moisture Grade For The Exact Panel
ARAUCO identifies Trupan Moisture-Resistant MDF as an interior product for applications involving high humidity and incidental moisture, available raw or TFL finished.
Ask for the selected panel's permitted exposure, finishing and edge-treatment instructions. Record how cut edges, openings and hardware locations will be addressed. Do not turn a moisture-resistant label or a decorative finish into a claim that the complete cabinet is waterproof.
Record The Complete Panel Choice
- Define The Part: Identify whether you are comparing a door, side, shelf or removable access panel, and record its planned dimensions and use.
- Compare The Finished Assembly: Include the chosen finish, edge treatment, framing and hardware in the weight and cost comparison. Obtain product-specific weight data or a measured part weight; do not substitute a generic sheet estimate for the completed cabinet.
- Check Access And Hardware: Confirm the hinge, slide, latch or removable fitting requirements for the selected panel and arrangement. Keep installation and service access visible in the layout and thickness model. The removable-fitting comparison identifies separate hardware questions.
- Keep Open Questions Visible: Record the supplier, full product name, grade, thickness, source date and any unresolved limit. Use the project decision record before ordering.
Keep the loaded cabinet’s joints and vehicle attachments with the framing and mounting records.
Original Cabinet Design Notes
- The original design notes proposed 3/4" MDF rather than 1/8" paneling.
- Instead of sliding the panel into the 2020 channel:
- The proposed attachment used straight pieces of aluminum.
- The notes describe bolting one side to the inside 2020 framing that holds the cabinet door.
- Instead of sliding the panel into the 2020 channel:
- A butcher block vinyl finish was considered for the MDF.
Panel Listed In The Original Notes
- Home Depot 3/4 in. x 4 ft. x 8 ft. Melamine White MDF Panel
- View At Home Depot
- Black vinyl was another finish considered in the notes.