AmericanWoodworker-ProjectPlan-GiantShopCabinet.pdf

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PROJECT PLAN
Giant Shop Cabinet
This project originally appeared in
American Woodworker
magazine.
For subscription information, visit www.americanwoodworker.com
Please note that pages that appeared in the magazine as advertisements will not be included with this pdf. Page numbering may be
interrupted if an advertisement ran within the original story. Addresses, phone numbers, prices, part numbers and other information
may have changed since original publication
Copyright© 2006 Home Service Publications, Inc. All rights reserved. Unauthorized reproduction, in any manner, is prohibited.
American Woodworker
is a registered trademark and
Workshop Tips is a trademark of RD Publications, Inc.
By Tim Johnson
Organize tons and
tons of woodworking
supplies with
room to spare.
f your workshop seems cluttered and your
workbench is always covered with stuff,
you need this cabinet. It packs 30 cubic ft. of
storage, enough for all of those got-to-have
supplies, from screws to paint cans. Everything
is readily accessible, without reaching, because
the big pantry-style doors open wide. We’ve
packed a room-full of storage into a cabinet the
size of a fridge—only 30-in. wide, 24-in. deep
and 6-ft. tall. Best of all, this cabinet is easy to
build. You and a buddy could whip together a
couple of these beasts over a three-day weekend.
Tools and Materials
Getting Started
To build this cabinet, you’ll need a tablesaw with
a 30-in.-capacity rip fence and an outfeed table,
a dado set and a router with a 1/2-in. diameter
straight bit. You’ll also need a drill/driver, a
bunch of clamps, glue, lots of screws, a hinge bit,
a hack saw and help from a friend to cut the big
sheets of plywood.
All of the materials you need to build the
cabinet, except for the rare-earth magnet door
catches, are available at your local home center
(see Sources and Shopping List, page 96). It can
be built for as little as $250. By using birch
88
A m e r i c a n Wo o d w o r k e r
DECEMBER 2001
Measure the thickness of your
sheet stock before you start cutting.
It’s often up to 1/32-in. thinner than
you’d expect. The Cutting List on page
96 shows which pieces will be affected
if you’ve got skinny plywood. It’s best
not to cut these pieces until you need
them, so you can adjust the
dimensions.
We’ve arranged the cabinet’s pieces
on the plywood so you can cut them all
to final size on your tablesaw, using
only the rip fence. You should recruit a
ART DIRECTION: VERN JOHNSON • PHOTOGRAPHY: BILL ZUEHLKE • ILLUSTRATION: DON RAYMOND
I
plywood and metal shelf standards and clips
throughout, we spent $350.You can save close to
$60 by substituting AB exterior grade
plywood, but it’s considerably harder to
work with. Besides, it’s just plain ugly.
Standards and clips work great to
mount the shelves in the outer doors,
but by mounting the ones inside the
cabinet with wooden cleats or by
drilling holes for shelf pins, you can
save another $25.
A m e r i c a n Wo o d w o r k e r
DECEMBER 2001
89
FIG.A:
CABINET AND OUTER DOORS
A4
A13
A11
A9
3/4'' X 3''
NOTCH
#6 x 1'' FH
SCREW (TYP.)
#6 x 1-1/4'' FH
SCREW (TYP.)
3/4''W X 1/2''D
RABBET
1/2''W X 1/2''D
RABBET
A1
A2
33''
A10
A1
B1
35''
B2
DADO
FOR A5
A5
A7
DADO
FOR A7
5/8''W
X 3/16"D
DADO
B4
B5
37-3/4''
31-3/4''
5/8'' WIDE
SHOULDER
A3
3/4''W X 1/4''D
DADO (TYP.)
3/4"W X 3/8"D
RABBET ALL
AROUND
A12
4''
4''
B3
B6
FIG. B:
BIRD’S-EYE
VIEW
#6 x 1-1/4'' FH
SCREW (TYP.)
A
B
D
Simple
glued-and-screwed
joinery makes
this cabinet
easy to build.
B
C
90
A m e r i c a n Wo o d w o r k e r
DECEMBER 2001
Caution:
The blade guard must be
removed for this cut.
Be careful.
EXACT
LENGTH
AUXILIARY
FENCE
FEATHER-
BOARD
HOUSED
DADO SET
CABINET
SIDE
WASTE
SHORT END
1
CUT THE CABINET’S LONG PIECES from the short end of
full-sized sheets.You’ll need a buddy to help maneuver the
ungainly sheet and keep the big offcut under control.With
careful measuring, the cut-off piece will be exactly the right length,
ready to be ripped to width.
2
RABBET THE CABINET SIDES for the top and back,
using an auxiliary fence (Part X1) and a featherboard.
By housing the dado set, the fence allows you to
match the width of the rabbet to the thickness of the
plywood top.The featherboard acts as a blade guard and
ensures a consistent depth of cut.
buddy to help you make the first cuts in
each sheet (Fig. D “Buddy Cuts,” in red). If
you’re a lone wolf, it’s safest to make these
cuts with a circular saw and a straightedge.
The long pieces (cabinet sides, center
divider, door fronts and frame sides) are
arranged so you can cut them to exact
length from the short end of the full-
length sheets (Photo 1). First, mark their
exact length on the plywood. Then, make
a second mark 1/8-in. beyond the first, to
mark the width of the saw kerf. Set the
fence to cut the distance from the waste
end of the plywood to the second mark.
Initial crosscuts leave most of the
cabinet’s long pieces cut to length. They
also result in manageable-sized pieces
that you can handle yourself. Crosscut
the remaining long pieces (one door
frame piece and the center divider) to
length the same way, from full-length
sections, after making an initial rip cut in
the fourth sheet of plywood. Convince
your buddy to stick around and help you
make these cuts, too.
Build the Cabinet
SPACER
3
ROUT PERFECT
DADOES FOR
THE SHELVES
with a 1/2-in. straight
bit and a T-square-style
jig made from scrap.
Make the wide dado in
two passes, the second
with a spacer held
between the jig’s fence
and the base of
the router.
JIG
FENCE
SECOND
CUT
WIDTH OF
FULL CUT
T-SQUARE
ARM
Rabbet the top and back edges of the
cabinet sides (Fig.A, Parts A1 and Photo
2). Then cut dadoes for the center divider
(A2) and fixed shelves (A3, A5 and A7).
I forgot to stop!
The phone rang
just as I was ready to cut the
stopped dado for the middle shelf.
Distracted by the call, I went back
to work and zipped right through
my stop mark.
Oh well, it’s only a shop cabinet.
The through dado won’t hurt
anything but my pride. Had I
thought of it, a clamped-on stop
block, instead of a pencil line, would
have kept me from screwing up.
Next time I’ll just let the phone
ring.That’s safer, anyway.
A m e r i c a n Wo o d w o r k e r
DECEMBER 2001
91

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