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20 Mart 2015 Cuma

Tile Top Plant Stand Plans

Free woodworking plans to build an inexpensive plant stand with a tile top.

I decided to add more plants to my home without first thinking about where to put them! So I came up with this simple yet attractive design for DIY plant stand that's easy to build. You can even build it with minimal tools or get the wood cut for you at the store. You can build one for as little as $8 or if you're building 3 of them the cost comes down to around $6 each depending on the wood you choose.
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2 Mart 2014 Pazar

Tips For Making Cabinets Square With A Circular Saw

Reader question on how to get square cabinets when cutting plywood with a circular saw and what to do when your cabinets aren't square. A lot of good information on how to buy a circular saw for cutting plywood too.

A couple of days ago I received the following email from Catherine regarding cabinets that aren't square.
Hi,

I just found your site and love it. I'm new to woodworking and want to know what tools you use keep boxes square? I see a lot of 90 degree clamps out there and wonder if you recommend any of them? Also, what do you do if your project isn't square? How can you adjust it? Say a cabinet or bookcase for example.

Thank you, Catherine
In a follow up email I found out she's cutting her plywood with a circular saw and guide with pocket screw joinery. Since this is how I also cut my plywood I'm very familiar with the problems. There are four main problems that can cause your cabinets to not be square. In this article I'll discuss what causes cabinets to not be square as well as how to prevent them. At the end I'll discuss what to do when things don't line up square.

I had planned to write a separate guide on how to buy a circular saw but Catherine's question brings up a lot of the points I wanted to address so I'm including that here.
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27 Şubat 2014 Perşembe

DIY Wall Mount Rack For Patch Panels

Free woodworking plans to build your own 19" wall mount rack for patch panels for your home structured wiring project.

Having the patch panels of your structured wiring installed in a rack instead is a little neater and in my opinion looks better than using smaller standoffs like wall mounts. The patch panels that have a little plastic bracket that attaches to the wall are not full 19" width. At least the one's I've seen anyway like this Intellinet 12-Port Cat6 Wall-mount Patch Panel . If you need more than 12 ports that means you're going to have to mount more than 1 of them and they're not much cheaper than getting a single 1U 24 port patch panel. I'm considering these Cable Matters 1U 24-Port Cat6 Unshielded Patch Panels because they have the plastic arm in the back that can support the cables.

You just need some way to mount the patch panels to your plywood structured media panel. In this article I'll provide plans for building a simple 7U wall mount rack for patch panels and as a bonus a simple 2U hinged bracket.
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29 Haziran 2013 Cumartesi

How To Build Frameless Base Cabinets

Free Frameless European style base cabinet plans that you can build for your kitchen, bathroom, office, home theater or other renovations. This is more than just how to build a base cabinet. It's practically everything you need to know about building frameless base cabinets before you begin. 

When I first tried to learn how to build cabinets I had a hard time finding all the information I needed. There was a little bit here, a little bit there, but nowhere did I find all the information all in one place. I did my best to combine most of what you need to know in one place to make things easier for you. It's a bit of a long read but if you're serious about building your own cabinets it to save money it's well worth the time. One book I commonly saw mentioned was Build Your Own Kitchen Cabinets (Popular Woodworking) by Danny Proulx which might be worth considering. I haven't read it myself.

Frameless cabinets are easy and affordable to build. They also provide more usable storage space over face frame cabinets. Over the years I've looked into different construction techniques for frameless cabinets and have put all that information together to help you build your own frameless base cabinets. To build matching wall cabinets see my post on How To Build Frameless Wall Cabinets. Construction of the base cabinet is relatively straight forward. The most difficult aspect is planning and sizing which will make up a good bit of this post.

Frameless cabinets have a more contemporary look but can be dressed up with trim and more elaborate doors to have a more traditional look.

In this article we're going to focus on how to build a frameless base cabinet carcass. The cabinet carcass is the main box of the cabinet which does not include doors, drawer fronts or drawer boxes. The cabinet carcass can be configured in a number of different ways to allow doors, drawers, open shelving or any combination which suits your needs.

The frameless cabinet design I find easiest to build, install and provides exceptional strength is the one pictured right. It is made of 3/4" plywood throughout, including a full back. The top consists of 2 4" stretchers. Up to a 30" wide standard base cabinet carcass can be constructed out of a single sheet of 4' x 8' plywood.


This is the design we'll focus on but I'll address some other options and aspects.

Cabinet Base Options

There are 4 different ways you can configure the base of your lower frameless cabinet. Each one has it's pros and cons.

Standard Base

The standard base has the sides and back of the cabinet extend all the way down to the floor and is notched in the front to provide a toe kick. The notch is 3" deep and 4-1/2" tall. There is a "sub toe kick" that provides additional support for the bottom and makes it easy to apply your finished toe kick cover (such as a decorative baseboard) over a continual stretch of cabinets for a seamless look.

This type of base is marginally more difficult to build and uses a little more plywood but you get a single cabinet unit which has advantages. Each cabinet needs to be shimmed individually to make it level. This is what most semi-custom cabinets you buy look like.

Standard Base No Toe Kick

Sometimes you won't need a toe kick at all such as when you're building a built-in desk or library. This base has the same pros and cons as the standard base except it has no toe kick. Instead a decorative board, the same thickness of the doors, is applied over the base of all cabinets after installation for a seamless look.

Adjustable Cabinet Legs

Adjustable cabinet legs (such as these Platte River Cabinet Leveling Legs or better Blum Leg Levelers and Blum Kick Plate Clips) make installation of cabinets very easy on uneven floors and let's face it, most floors have some degree of unevenness to them.

What's more, it's easy to make changes to the cabinet height during installation (and with a little more work after installation) if the need arises.

The toe kick board gets screwed onto a plate that clips onto the legs after all cabinets have been installed and leveled. Unlike the standard base, it's easy to add a toe kick on the side of a cabinet such as the exposed end of a cabinet run. It also makes it easier to change the toe kick board to change the look of your kitchen at a later date.

Since the wood cabinet is kept off the floor these are good for spaces where dampness is an issue such as in basements, garages or other areas where cabinets are installed on a concrete slab floor.

The downside is it will add a little bit extra to the cost of each cabinet but not much and the benefts will usually outweigh the cost.

Separate Base Platform

Finally you can create a separate base platform that consists of a frame made up of 2x4's with a plywood top giving you a total toe kick height of 4-1/4" (3-1/2" 2x4 + 3/4" plywood). What's nice about this arrangement is you level the platform before installing the cabinets. Then you just need to place your cabinets on the platform without having to do much if any additional leveling. The base is also sturdier than a base that is part of or attached to your cabinets.

You can even create toe kicks on the sides of cabinets where necessary such as the end of a cabinet run or a kitchen island.

Cabinet Back Options

You also have a few options on how you construct the back of the cabinet.

Full Back

You can choose to use a full back that is the same 3/4" plywood used for the rest of your cabinet. (Some people choose to use 1/2" but I find it's easier to just use one thickness throughout.) This configuration will give you an enclosed cabinet with exceptional strength which is important when installing heavy stone countertops and supporting heavy countertop appliances. It can be a little more money but not much if you plan your cuts out well. We'll be using the Full Back in the example in this article.

Nailer Back

Sometimes you don't care if a cabinet has a back or not, such as in garage storage cabinets. This option can save on material. Instead of having a full back you create 2 nailing strips out of 3/4" plywood for the top and bottom of the back so you have something to affix the cabinet to the wall with and to provide rigidity and strength to the cabinet.

1/4" Back With Nailers

In some cases you'll want to have an enclosed back but you want to save some money. You can use nailers as in the previous option but also staple a 1/4" plywood back over the nailers to provide a finished look. This is cheaper than using a full back and provides a lighter cabinet. Many semi-custom cabinet manufacturers use this technique. It doesn't add as much strength as a full back but it does give you the look and feel of one. The 1/4" plywood is more prone to warping than the 3/4" plywood and may bow out over time.

What You'll Need

Tools

Materials

3/4" hardwood veneered plywood is the best option for building your cabinets. If you're taking the time to build your own cabinets might as well make them the best you can. You're still going to save money over most semi-custom cabinets that are usually made out of 5/8" particle board and wind up with a better quality cabinet. 

Plywood comes in different apperance grades. A1 being the best. If you plan on painting your cabinets or don't care about the apperance (garage cabinets) you can use a lower appearance grade cabinet. If you must use MDF to save money make sure you glue your joints in addition to using the appropriate pocket screws . 

Step 1: Calculate Cabinet and Component Dimensions

Chances are you will want to build a different sized cabinet than what I'm going to show in this example. In most cases you'll want to build multiple cabinets of different sizes so let's go over how to calculate the dimensions of the different components that make up the carcass. 

Cabinet Height

The height of the cabinet will be determined by the application. For example the standard height for the top of a kitchen work surface is 36". If our countertop thickness will be 1-1/2" that means our cabinet needs to be 36" - 1-1/2" or 34-1/2" tall.

Cabinet Height = Desired Top Height - Top Thickness

Some common work type heights are:
  • Kitchen 36"
  • Bathroom Vanity 33" to 36"
  • Desk 30"

Cabinet Depth

The standard depth for kitchen cabinets is 24" which includes the door. This should work for most situations but you may want to check the specifications of your appliances (slide in range, dishwasher, etc) to see if they require a different size. 

For bathroom vanity cabinets the standard depth is 21". For desks and other custom cabinets you can choose whatever depth works best for you though most are 20-30" deep.

Cabinet Width

This one is easy. The cabinet width is determined by your design and your preferences.

Cabinet  Component Dimensions

In our example we're going to be constructing a 30" W x 34-1/2" H x 24" D cabinet using 3/4" plywood. We'll be making it with a standard base and a full back. In all the dimensions below the direction of the grain will follow the height.

*Note: if you're using thick edgebanding you'll need to factor that in where appropriate. Most edgebanding is less than 1/32" thick which is pretty insignificant so I don't factor it in most of the time. As long as it's used consistently and applied before assembly I consider it an acceptable margin of error. Wood expands and contracts. Not all human cuts are very accurate. Consistency is more important over precision and it makes calculating sizes and cutting components much easier.

Cabinet Side Dimensions

We will need two sides for the cabinet. The height of the side is simply the height of our cabinet minus an external base if using one. The width is the depth of the cabinet minus the thickness of the door.

Cabinet Side Height = Height of Cabinet - External Base (34-1/2" - 0 = 34-1/2")
Cabinet Side Width = Depth of Cabinet - Door Thickness (24" - 3/4" = 23-1/4")

We'll need 2 34-1/2" x 23-1/4" sides for our cabinet.

Cabinet Bottom Dimensions

The height for the bottom of our cabinet will need to be the width of our cabinet minus twice the thickness of the sides. The width will be the depth of the cabinet mins the back depth minus the door thickness. (Be careful sometimes advertised size isn't true size. A digital caliper can help you get an accurate thickness measurement. Your 3/4" plywood may sometimes be 23/32" or something else entirely.)

Cabinet Bottom Height = Cabinet Width - 2 x Side Thickness (30" - 2 x 3/4" = 28-1/2")
Cabinet Bottom Width = Cabinet Depth - Back Thickness - Door Thickness (24" - 3/4" - 3/4" = 22-1/2")

We'll need one back that is 28-1/2" x 22-1/2".

Cabinet Shelf Dimensions

If you're installing a shelf in your cabinet (as our example does) you want to size it appropriately. It's basically the same dimensions as the Bottom minus a little depth (1/2") so that it stays clear of the doors even if there is some expansion.

Cabinet Shelf Height = Cabinet Bottom Height (28-1/2")
Cabinet Shelf Width = Cabinet Bottom Width - 1/2" (22-1/2" - 1/2" = 22")

Cabinet Back Dimensions

We can use some of the previous dimensions we calculated to determine the dimensions of the back of the cabinet. The back of the cabinet will rarely be seen and even when it is it won't be lit very well. While it's nice to have a consistent grain direction for the backs you might be able to save a sheet of plywood by mixing the grain direction up for the backs if you don't mind a little inconsistency in an inconspicuous location.

Cabinet Back Height = Cabinet Bottom Height (28-1/2")
Cabinet Back Width = Cabinet Side Height - Stretcher Thickness (34-1/2" - 3/4" = 33-3/4")

Our cabinet needs one back measuring 28-1/2" x 33-3/4".

Stretcher and Sub Toe Kick Dimensions

Grain direction should be along the long side but in most cases these components will hardly be seen so feel free to change the orientation if it helps you maximize the usage on your cut plan. 

Stretchers should be 3-4" wide, the sub toe kick should match the height of the notch cut into the base (4-1/2" in our example). The height of both should be the same as the Cabinet Back Height (28-1/2").

We'll need 3 stretchers (4" x 28-1/2") and one sub toe kick (4-1/2" x 28-1/2")

Step 2: Attach Side To Back

Wow! You've read all this way and we're just starting to put the cabinet together! Careful planning makes the rest of the process easy.

Start by applying edgebanding to the front of both cabinet sides.

Drill pocket holes around the top and sides of the Cabinet Back and attach it to one of the sides as shown.


Notice that the bottom of the back is flush with the bottom of the side. There is a 3/4" space on the top of the back for the stretcher that will eventually be installed.

Step 3: Attach Bottom

Apply edgebanding to the front of the bottom, drill pocket screw holes as shown and attach the Bottom to the Side and Back previously assembled. Notice that the bottom of the Bottom is flush with the notch for the Toe Kick. Use your square to make sure everything is aligned properly.

Step 4: Attach Other Side

Attach the other side to the cabinet assembly using the previously drilled pocket holes in the Back and Bottom pieces.

Step 5: Attach Stretchers

Apply edgebanding to the front of the 2 stretchers that will be attached to the front. Drill pocket holes and attach to the cabinet making sure everything is square. The bottom stretcher on the front is for the first drawer. To minimize visibility of the pocket holes install them with the pocket holes facing up. (The drawer will hide the second front stretcher holes.)


In this example we're assuming the cabinet will have a single full width drawer and 2 lower doors. The spacing for this bottom section will be determined by the desired drawer height. The standard top drawer height is 6". We're planning for overlay drawers and doors. A 1/4" gap should be on the top to avoid any binding against the counter top. That means the second front stretcher should be 6-1/4" down from the top of the cabinet.

Step 6: Install Sub Toe Kick

The Sub Toe Kick helps support the cabinet and add rigidity. It also makes it easy to nail in the finished kick board after installation. Drill pocket screw holes and attach it between the cabinet sides as shown.

Step 7: Drill Shelf Pin Holes

Using the Kreg Shelf Pin Jig make holes in the back and front of each side of the cabinet for shelf pins. Leave at least 3-4" on the top and bottom for room to install your door hinges depending on where you drill the bores for your hinge cups on the door.

Use the short side of the jig without the fence to get the holes 37mm from the front edge of the jig. When doing the back, flip the jig around.


When you're done, apply edgebanding to the front of the shelf, insert shelf pins in the appropriate locations and install your shelf.

To learn how to make drawers see my post on How To Make Drawer Boxes

24 Haziran 2013 Pazartesi

How To Build Frameless Wall Cabinets

European style frameless upper cabinets are easy to build with the right tools, are affordable and are used for a variety of projects from kitchens, to bathrooms, offices and more. When I first tried to find information on how to build my own cabinets I found it a bit confusing. In case it helps others I'm going to go over what I've learned over the years. In this post you'll find information on frameless upper cabinet construction and instructions on how to build them.

These basic wall cabinets have a very clean, contemporary look but frameless cabinets are versatile. By using nicer doors, adding some crown molding and light rail trim you can achieve a more traditional look.



You can save a lot of money if you build your own frameless cabinets. While building frameless cabinets isn't very difficult it is important that the cuts are accurate and the pieces as well as the assembly is square. Before you go crazy in your kitchen with a sledgehammer and order a large pile of plywood Try to build one small cabinet to make sure you're happy with your results.

What You'll Need

Tools

Materials

You'll need 2 sides, one top, one bottom, one back, one or more shelves and one or more doors. 

Unlike my other posts, there is no cut list or cut plan because these are general instructions and the size of the cabinet will vary based on your needs. Instead I'll provide information on how to calculate the dimensions of the components you'll need to build your own cabinets to your specifications.

The type of material you choose will depend on where you will be installing the cabinets. In your kitchen you'll want to use nicer material than in your garage.

Material for Cabinet Carcasses

The cabinet box is also called the carcass. The thicker the material you use, the stronger the cabinet will be and the longer you can make your cabinets. 3/4" material is recommended but in some situations 5/8" or 1/2" can also work. Some woodworkers use different thicknesses for different parts of the carcass such as 1/4" backs inserted into a groove with 1/2" nailing strips, or 1/2" for the back and sides and 3/4" for the top and bottom. This is mainly done to save money. If you're only building a few cabinets for yourself you can simplify the process and wind up with stronger cabinets if you just use the same thickness material (3/4") for all the components.

Plywood is better than MDF is better than particle board. If you're using plywood it's important to note that plywood comes in different grades. One grade for the good side and one grade for the back side. A1 is the best appearance grade of plywood you can get. If you want to save some money you can choose to build the carcasses out of a lower appearance grade plywood such as B2 and use the A1 plywood for exposed ends and doors. Some even like to use melamine coated particle board for the carcasses with better plywood for doors and end panels. If you plan on painting your cabinets the grade of the plywood isn't as important. 

For shop cabinets in the basement or garage you might be able to find "shop grade" plywood at your local lumber mill. This plywood would have more defects in the veneer but still have a strong core. Many people even build shop cabinets out of CDX plywood. It's not very pretty but the X in the name indicates the glues used can handle a bit of exposure to weather which could be good in a garage.

If you're going through the trouble of building your own cabinets you're already saving a considerable amount of money and it makes sense to go with plywood in most instances. For the purpose of these instructions I'm going to assume the cabinet will be built with 3/4" plywood.

Material for Cabinet Doors

You can make plain slab doors out of the same material you use for your cabinet carcasses. In our case plywood. This will be the cheapest option and the one I'll be using in this guide because there are too many options and methods to construct cabinet doors to discuss here.

If you're not happy with a plain slab cabinet door a number of companies will make custom doors for you in a variety of styles at reasonable costs.

Step 1: Calculate Cabinet Component Dimensions

Before we begin cutting and assembling our cabinet we first need to determine what size cabinet we need. If you've ever gone to a kitchen showroom you've probably noticed that the semi-custom cabinets they offer come in some standard sizes. Since we're building our cabinets we can choose any custom dimensions we want to suit our needs. There are some limitations however. The material and thickness chosen will decide how wide a cabinet we can build. In most cases with 3/4" plywood about 42" should be the maximum width but narrower cabinets will have more stability.

Standard upper cabinet depth is 12" (including door) when over a counter. Deeper when over a refrigerator and has more support. The 12" upper cabinet depth leaves a 10-1/2" interior depth. Dinner plates are usually 10" in diameter but can up to 12". If you have larger plates, or want to leave room for larger plates in the future, make your cabinets deeper. In our tutorial we'll build a frameless upper cabinet that is 18" W x 30" H x 12-1/2" D. This will leave an 11" interior cabinet depth.

Our cabinet will be made up of 6 pieces of plywood. 2 Sides, a top and bottom, a back and a door. All will be cut from 3/4" plywood. To determine the size of each component we'll use the following formulas.

(For consistency the "height" is also the direction of the grain.)

Cabinet Side Dimensions

There are 2 sides and in most case the dimension runs vertically. The height of the side is the same as our desired cabinet height. Because we're using overlay* doors the width of the side is our desired cabinet depth minus the thickness of the door.  In our case we have:

Side height = 30" (height of cabinet)
Side width = 12-1/2" - 3/4" (depth of cabinet - width of door) = 11-3/4"

We'll need 2 11-3/4" x 30" pieces of 3/4" plywood.

(Overlay doors sit in front of the cabinet. Inset doors sit within the cabinet. For inset doors the width of the sides will be the same as the width of the cabinet.

Cabinet Top/Bottom Dimensions

The top and bottom pieces have the same dimensions. The width of the top/bottom is equal to the depth of the cabinet minus the thickness of the door. The height of the top/bottom is the width of the cabinet minus the thickness of each side.

Top/Bottom height = 18" (cab width) - 2 x 3/4" (side thickness) = 16-1/2"
Top/Bottom width = 12-1/2" (cab depth) - 3/4" (door thickness) = 11-3/4"

We'll need 2 16-1/2" x 11-3/4" pieces of 3/4" plywood.

Cabinet Back Dimensions

The back of our frameless cabinet fits in between both sides and the top and the bottom. To determine the width of the back we need to subtract the thickness of each side piece. To calculate the height we subtract the thickness of the top and bottom pieces.

Back height = 30" (cab height) - 3/4" (top thickness) - 3/4" (bottom thickness) = 28-1/2"
Back width = 18" (cab width) - 2 x 3/4" (side thickness) = 16-1/2"

We'll need 1 28-1/2" x 16-1/2" piece of 3/4" plywood.

Adjustable Shelves Dimensions

Depending on the height and purpose of the wall cabinet you may want to have one or more adjustable shelves. These are peices of 3/4" plywood that rest on shelf pins which are inserted in a series of shelf pin holes inside the cabinet.

The shelf is the width of the inside of the cabinet and extends from the back of the inside to 1/4 inch from the front.

Shelf height = 18" (cab width) - 2 x 3/4" (side thickness) = 16-1/2"
Shelf width = 12-1/2" (cab depth) - 3/4" (door) - 3/4" (back) - 1/4" (space) = 10-3/4"

Cabinet Door Dimensions

Our cabinet only has one door and we are designing the cabinets to be full-overlay. This means that the door sits in front of the cabinet and covers almost all of the cabinet. In reality the door needs a little bit of space around it to prevent it from rubbing against adjacent doors or walls. 



The minimum space with most hinges is 1/16" so we need to subtract 1/8" (2 x 1/8") from each dimension. That will also give us a nice 1/8" spacing between doors from other cabinets too. 

Door height = 30" (cab height) - 1/8" = 29-7/8"
Door width = 18" (cab width) - 1/8" = 17-7/8"

If we were building a wider cabinet that required 2 doors we would still subtract 1/8" for the height but the width of each door would be (CabHeight - 1/4")/2. There would be a 1/8" space between the two doors and 1/16" space around the perimeter.

Now that we know what size pieces of plywood we need we can begin assembly.

Step 2: Assemble Sides, Top and Bottom

Should you use glue? Pocket hole joinery is pretty strong but glueing the joints in addition to screwing will give you a stronger more rigid cabinet. If you do decide to use glue, first assemble the cabinet without glue to make sure everything fits and lines up well. Then disassemble and reassemble with glue.

Edgebanding: Apply edgebanding to the edge of each of the 4 pieces that will be on the front of the cabinet.

Start by drilling pocket holes in the Top and Bottom pieces as shown and attach the Top to one of the side pieces.

Now attach the bottom to the side. Make sure the pocket holes are on the outside of the cabinet.


Attach the last remaining side, making sure everything is aligned properly and square.

Step 3: Cabinet Back

Double check to make sure the back of the cabinet is square and make sure it fits inside the back of the cabinet. If not, make adjustments to the back.

If everything fits together properly, is the right size and is square, disassemble the cabinet and repeat Step 2 above, this time with glue before inserting the back.

Drill pocket hole screws around the perimeter of the back and attach it to the rest of the cabinet as shown using glue.

Because we're using pocket screws we've built this entire cabinet without a single clamp. Normally a lot of long, expensive bar clamps are used when building cabinets or other furniture to keep the cabinet in place while the glue dries. One of the benefits of using pocket hole joinery is the screws act like clamps to hold everything together while the glue dries.

Step 4: Drill Shelf Pin Holes

Remove the fences from your Kreg Shelf Pin Jig and place it at the bottom of the cabinet as shown. The short side should be flush with the front of the cabinet. This will position the holes 37mm away from the front.

Use the second and third holes from the bottom to drill pilot holes for the hinge mounting plate.

Slide the shelf pin jig up to the top of the cabinet, keeping it flush with the front of the cabinet and drill holes for the top hinge mounting plate in the 2nd and 3rd holes from the top as shown. 


Now place the indexing pin in the bottom hole of the jig, slide the jig down to insert the indexing pin in the 1st Shelf Pin Hole drilled previously and continue your way up the side of the cabinet drilling shelf pin holes. Stop before you get to the pilot holes for the top hinge mounting plate.


Flip the shelf pin jig around and place it in the back corner of the cabinet so the short end of the jig is closest to the back as shown. Drill the 1st shelf pin hole in the last hole from the bottom. (We don't need pilot holes for the hinge in the back.)Then continue drilling the remaining shelf pin holes along the back using the indexing pin.


Repeat this step on the other side of the cabinet.

Step 5: Mark Hinge Bore Locations

On the back, hinge side of the door, mark 2 lines 3-3/16" from the top and bottom of the door. This is the center-line for the hinge bore.

Follow the instructions that came with your hinge boring jig (such as the Rockler Jig It Concealed Hinge Jig) to drill the 35mm bores for the cup end of the hinge. 

Finally attach and adjust your hinges so the door has an even overlay all the way around the cabinet.

Insert some shelf pins, and your shelf and the cabinet is done. Paint and prime, or stain and finish.


9 Şubat 2013 Cumartesi

Easy Small Closet Organizer Plans

Free woodworking plans for a reach in closet organizer that provides double hang, long hang, shoe and sweater shelves for a small closet.

My previous small closet organizer design provided a lot of storage for a narrow closet but it may be a little too complex for some to build. This new design is easier and cheaper to build. If you use MDF you can organize your closet for around $50. It doesn't provide as much shelf storage but it still has plenty of double hang as well as long hanging space and shelves for shoes and sweaters. With a closet this small you're going to need a dresser to store folded clothes anyway so that much shelving isn't as important.

If your current closet only has a typical single rod and single shelf you can see how much space gets wasted. With a little bit of wood and a few hours of time you can dramatically increase the space utilization of your closet. If you've been dealing with a small  3'-4' closet you know how important it is to squeeze as much extra storage as possible.

Good shoes are expensive and just tossing them on your closet floor increases the likelihood they get damaged. Shoe shelves help protect the investment you've made in your shoes.

Providing space for long garments is also important and this organizer allows you room to hang up some of those long dresses or coats so you don't have to run to another room for them.

The Right Hangers Save Space
I've designed the storage unit so that the interior shelves are 14" wide. That will hold folded clothing comfortably as well as 2 pairs of womens shoes side by side or one pair of mens shoes on each shelf. If you want less shelving space and more hanging space you can choose to make the shelving unit narrower (or wider for more shelvnig less hanging).

You can customize the dimensions of these plans to better suit your needs just keep in mind these general guidelines. The shelving unit needs to be 42" tall to be able to hold the double hanging rod. Women's shoes generally need about 7" of width, mens shoes 9" and sweaters and other folded clothing 12". Every body is different so measure how much space your clothes take and see if you need to customize the plan to get more efficient use.

What You'll Need

Materials

Tools

Cut List

  • (5) ~12" x 14" Shelves 3/4" Plywood
  • (2) ~12" x 9" Shoe Shelves 3/4" Plywood
  • (2) ~12" x 42" Shelving Unit Sides 3/4" Plywood (See Cut Plan for exact shape)
  • (1) 24" Rod Support 1x4 Board (or whatever the depth of your closet is)
  • (2) 14" Stretchers  1x4 Board
  • (2) 18" Shoe Shelf Supports 1x2 Board 

Cut Plan

3/4" Plywood

The first quarter sheet of 3/4" plywood will be for the shelves. You may want to alter the number and width of the shoe shelves depending on your design. The depth will be slightly less than 12" because of the kerf of the saw. Do your best to cut it as evenly down the middle as possible.
The second sheet is where we'll cut the sides for the shelving unit. To be able to limit the amount of plywood necessary the cuts aren't simple straight cuts. Again, the depth at the middle will be a little less than 12" due to the saw kerf. It's probably best to cut this out with a jig saw.

Boards

1x4: Two lengths of 1x4 need to be cut to the same width as the shelves, in our case 14" and one length that is determined by the depth of your closet for the lower rod support on the side wall.

1x2: One shoe support needs to be cut from 1x2 material for each side shoe shelf. The support needs to be long enough to reach from the back corner of the closet to at least the first side wall stud so that it is screwed securely at each end.

Step 1: Cut Lumber and Finishing

To minimize the time that the closet is out of service we're going to build much of the closet organizer before installing it. This includes finishing the wood so that it's dry when it's installation time. If you don't have a lot of space to lay all the plywood out flat to paint, you might find it easier to paint after you've assembled the shelving unit or just paint everything after installing but you'll have to wait until it dries before using the closet.

Double check your closet measurements and make any modification you need to the cut plan if you choose to customize the size based on your needs.

So that we can get 2 sides out of one 2' x 4' sheet of plywood they're not cut straight. Start off by cutting the board down to 42" in length. If you're comfortable making plunge cuts with a circular saw it's the best way to cut the horizontal cuts. The vertical cuts and rounded corners are best cut with a jig saw. You can also use a jig saw to make the entire cut just take your time and use a straightedge to get the cuts as straight as possible on the long stretches.

You may also want to increase the 4" to 6" or so for a little extra flexibility in positioning the lower rod.


Once you have the 2 sides cut out, a notch will need to be cut out at the back bottom of each side to fit around your baseboards.

Once everything is cut, prime and apply two coats of water based paint. Let everything dry at least 2 days before continuing. Let the paint cure for at least a week (more if weather is humid) before placing items on the painted surfaces.

Step 2: Attach Top to Side

The shelving unit consists of 2 sides, 2 stretchers and 2 fixed shelves. We're going to begin constructing it by attaching the fixed top to one side using pocket hole screws from underneath.


Note that the back of the top is flush with the back of the side and the notch cut out in the back/bottom of the side for the baseboard so it will fit close up against the wall. The front of the top does not extend all the way to the front of the shelving side.

Step 3: Attach Bottom Shelf To Side

Next we'll attach the bottom to the side. The shelving unit needs 2 fixed shelves to make it sturdy. The location of the top shelf needs to be at the top but you have some flexibility when positioning the bottom shelf.

I've planned for the bottom of the bottom shelf to be 12-1/2" from the bottom of the side but depending how big the items you plan to store in that area are, you might want to increase or decrease it. For example, if you want to store boots you may want to increase it.

Make sure the side is square to the front of the side and attach it using pocket hole screws as you did the top.

Step 4: Attach Stretchers To Side

Two stretchers cut from 1x4 boards are used to provide a way to attach the shelving unit to the wall as well as provide extra strength. Using pocket screws attach them to the side and fixed shelves as shown.


The bottom stretcher needs to clear the baseboard notch. If you want the shelf lower, mount the stretcher above the bottom shelf instead of below it.

Step 6: Attach Other Side

Finally we'll attach the other side of the shelving unit using the previously drilled pocket holes in the fixed shelves and stretchers. It's important that everything gets screwed together square.

Step 7: Drill Shelf Pin Holes

With the shelving unit completed we can now drill 2 rows of shelf pin holes on each side of the shelving unit. This is much easier to do with a jig like the Kreg Shelf Pin Drilling Jig.

For each set of holes use the same reference point. For example start all sets of holes by resting the bottom of the jig against the bottom shelf.

If you don't have a pocket hole jig you can either screw the shelves in directly using pocket hole scres or you can manually mark and drill the holes for the shelf pins. 1-1/4" spacing 2" from the front and back should do it.

Step 8: Move Existing Rod and Shelf

With the shelving unit complete and the rest of the components primed and painted it's time to start preparing the closet. To save some money we're going to reuse the existing rod and shelf. A typical closet has it's shelf installed at around 66" above the floor. 


To accommodate a double hang space the shelf and rod are going to need to be moved further up so that the bottom of the top shelf is at 84" above the floor.

Typically the closet will have 1x4 boards installed at the 66" mark on three walls that will support the shelf and rod. Try and determine how the boards are attached to the wall. They're probably just nailed in but sometimes they'll be screwed in.

Start by trying to remove the top shelf. Run a utility knife around the edges where the shelf meets the walls and 1x4s to break any paint that might be helping keep them together. Use a prybar to lift the top shelf off. If it's not coming up easily check for any screws and unscrew them.

Next the closet rod should be easy to lift off. 

Finally start removing the 1x4 support boards. We want to reuse all these pieces so take your time and try to avoid breaking them.

Use a level to draw a line as a guide to reinstall the existing closet rod and shelf. The tops of the support boards need to be at 84". To make installing easier draw your level reference line at 84" minus the width of board. Your boards may vary but if they're 1x4's they'll be 3-1/2" wide. So draw a line at 80-1/2" above the highest point on the floor.

Now reinstall the support boards into the closet lining up the bottom of the boards with the reference line. That should put the top of the boards at 84".

Place the rod back in and then attach the shelf.

There will be some holes in your walls and mismatched paint so fill in any holes with spackle, and sand any paint edges. When the spackle dries, sand it smooth then prime and paint the entire closet. For a closet, water based low VOC paint like Benjamin Moore's Aura is a good idea so that your clothes don't wind up smelling like paint.

Step 9: Install Shoe Shelf Supports

Before installing the shelving unit it's a good idea to install the wall supports for the side shoe shelves now that there's plenty of room to work. Typically, shoe shelves are installed 7" apart but you can change that to suit your needs. Keep in mind that the shoe shelves will reduce the height of the long hang area. If you have especially long garments to hang you might want to limit the number of shelves you're installing. If you use special pants hangers on the lower bar of the double hang section there should be sufficient room for shoes underneath your pants if extra shoe storage is important.

The shoe shelf supports are cut from the 1x2 boards. Make sure you cut them long enough so that they can be attached to at least 2 studs near the ends of the support.

Draw two level lines on the side wall, one 7" up and the other 14-3/4" up from the floor. (Or more or less depending on how high your shoes are.) Use these lines as a guide to align the tops of the 1x2 boards and drill or nail them into the studs on the side wall.

Step 10: Install Shelving Unit

Position the completed shelving unit against the back wall. It's position in relation to the sidewalls will determine how much extra hanging space you get via the double hang section as well as how much long hanging section you have. In this design I chose to put the shelving unit 9" from the left side wall. That will provide 9" of long hang which is enough to hold 4-6 long hanging items. If you need more or less you can position the unit as you see fit. I think it's a good idea for all closets to have at least some long hang area.

The position of the shelving unit will also determine the length of the extra shoe shelves on the left. Since you should have cut out the shoe shelves before this point you can rest one of the shoe shelves on the shoe shelf support and use it to determine where to position the shelving unit.


Once you have the shelving unit where you want it, make sure it's level and plumb then secure it to the wall by screwing it into studs through the back stretchers. 

Step 11: Install Lower Rod Support

The lower rod support is a 1x4 board that is cut to be as long as the depth of the closet. Screw or nail it into studs on the right wall so that the top of the support is 42" above the floor. You can also draw a level line from the top of the shelving unit to determine where to position the support. Make sure it is installed level.


With the rod support in place you can now install the closet rod. Directions will depend on what rod you use but it's important that the top-center of the rod is about 12" away from the back wall and about 1-1/2" down from the top of the shelving unit top and that the rod is installed level.

Step 12: Install Shoe Shelves

To install the shoe shelves, pocket holes will be drilled on the underside of the right side to attach to the shelving unit. On the wall side screws will be drilled from the top down into the wall supports. Drill pilot holes and countersinks so the screws are flush with the top or you can simply nail the shelves in place. Pilot holes are a good idea to prevent splitting the wood.

Step 13: Install Adjustable Shelves

Push the shelf pins into the appropriate holes depending on how you'd like to space the shelves in the shelving unit. Then place the shelves on top of the pins. Once the paint dries you can fill up your closet again.

If you'd like to add a drawer or two see my instructions on how to build drawer boxes.