Full extension IKEA ALEX drawer mod

This hack allows you to make an IKEA ALEX's drawers open to 100% extension with only printed parts and a few screws, no cutting required.  It reuses the ALEX's slides and most of the hardware.

WARNING.  TIPPING HAZARD.  Secure your ALEX to the wall so it can't fall forward when the drawers are opened all the way.

I modeled this in Fusion 360.  I've included the CAD files in .f3d and .STEP formats for easy remixing.

(Yes, I lined my drawers with 16 gauge galvanized steel.  (0.3mm)  You should too.)

UPDATE 7-Sep-2025: Added the .f3d and .STEP files.

Caveats

• This fits the wide ALEX.   I don't think it fits the narrow version.
• It's too big to print on a Prusa or Bambu Mini.  It fits comfortably on an MK4 and larger.
• You'll use about 1.8 Kg of filament for all six drawers.
• You may destroy the old drawer sides disassembling the ALEX, so you can't go back.

Parts Required

For each drawer, you'll need 8 screws.

Instructions

Printing

I wasn't able to print the back halves cleanly with supports.  So I made support blocks that fit in the slots for the drawer backs.  N. B., the drawer will not close easily if the bridges above those slots sag.  Either use the support blocks or file the slots until the piece thickness is 9.4mm or less.

To use the support blocks, first print two copies of support block.stl in a material that doesn't adhere to your main material.  I used PLA for the drawer sides and PETG for the support blocks.  Then, in the slicer, add a pause at the beginning of the first layer after 3.00mm (e.g. 3.20mm for 0.2mm layer height).  I've included a .3mf file with the pause that may work for you.  The support block clamps firmly onto the print.

I suggest printing the bushings and expanding plugs in PETG too.

If you have a woodworker's clamp, you can use the included caul to safely pry the drawer apart.  I included a caul that fits the Dewalt DWHT83193 clamp in the photo and a generic one that should work with any clamp.  Print two cauls.

Assembly

Remove and disassemble the drawer.  Separate the sides from the back as gently as possible; try not to damage the back.  Use the cauls if you have a clamp and rock the pieces apart.  (See photo.)

Join the halves of each side at the jigsaw joint.  Insert M3 screws through the joint from the top and bottom.  (See photo.)

Screw IKEA's side screws through the bushings.  Hold the bushings in pliers if necessary.  (See photo.)

Assemble per IKEA's instructions.  When you attach the back, use the expanding plugs instead of IKEA's nylon nail things.  Clamp or otherwise press the sides together and insert the expanding plugs.  Insert the M2.5 screws while it's clamped.  (See photo.)

Replaces the entire drawer slides instead of using an insert.