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Blog entry by BertFlores58 posted 10-11-2010 06:49 AM 1512 reads 0 times favorited 5 comments Add to Favorites Watch
« Part 1: The Bedroom new look ... A study room Part 2 of UNPOSTED PROJECTS -- NOW POSTED series Part 3: Multiple drawers from scraps »

In saving space, making one piece out of two functions will be a nice way of making tailored furnitures. There are lots of variation, a two piece sets and some are built separately and screwed together. This project started after I built the Agnes’ shelve blogged on first part. The design came in due to the need of storing hutch and a display shelve. There are some challenges such as.

1. The design requirements
I have a very limited space… 40 inches width x 6 1/2 ft high. The depth needs to be 16 inches inside to accomodate most of the containers. A full swing door that will carry a weight of a rice container 15 kg load. The door must be at least fully enclosed that no insects can go inside (how????) The shelve must be strong to hold heavier object. It must stand stable.

2. Recycled Materials
No money must be involve and use the old door jambs. Plywood would be okay. Minimize use of new things such as varnish or any materials that will be a part of cost. I was worried about joining 2×2 end to end to make longer post but I manage to join them ….. a beveled lap joint glued together.

one jointed post

and the other…

3. Mortise and Tenon
Strong and rigid design that I have to use mortise and tenon… Actually, I decided to use this joints as my personal challenge. I want to test my patience in dealing with router (portable), chisels and without the use of dowels. (Part 1 of the series, I experienced that dowels may not be required if strength of the flooring or the shelve is already attached.) When I connected the framework… yet without glue, it was strong with 50 mortises and tenons.

4. Hutch Doors
I got a different situation here from a normal work. I have previous plywood that was from a table that will be recycled however half of it is 1 inch thick (laminated with 1/4 plywood+3/4 plywood) and the other was only 3/4. I have to laminate 1/4 ply to compensate the thickness and make two doors. Definitely it was an extraornary plywood thickness to become a door. I have to make a full swing door and strong hinges. I have to pause on this part because I need to think what sort of hardwares I have to use.

Stained and finish.. I mixed a different blend of stain and painted thick to have uniform color.


The front upper

The Back. I used recycled 1/4 ply as back cover. One side was already painted white.

The Lower hutch with door. Notice that the doors are brown colored and I did not take out the color and use it instead.

Till next

-- Bert

5 comments so far

View Cozmo35's profile


2200 posts in 3061 days

#1 posted 10-11-2010 02:34 PM

Nice blog Bert. I still love the fact that you used recycled materials to build this great looking piece!!

-- If you don't work, you don't eat!.....Garland, TX

View BertFlores58's profile


1698 posts in 2947 days

#2 posted 10-11-2010 03:14 PM

Thanks Mike… It is already part of my life that I will use old and recycled wood. Though, here in Philippines, nothing is impossible. Recyclables are for sale but what I do is look from the source… at our office, when they renovate and change the partitions, the scraps that were taken out are really good lumbers and still reusable.

-- Bert

View Armand's profile


232 posts in 2936 days

#3 posted 10-13-2010 07:49 AM

Nice progress on your workpiece Bert. Keep it up. Just a question from a newbie woodworker here: How did you attach the plywood on the sides? Did you route grooves on the side posts? Im in the middle of building an entertainment center but have no router but plan instead to glue thin pieces of woods so plywoods can be attached to them. Am in the right direction? Thanks Bert for posting this.

-- My Master is Mankind's Greatest Carpenter.

View BertFlores58's profile


1698 posts in 2947 days

#4 posted 10-13-2010 08:52 AM

The back plywood was 1/4 and just make a dado or shoulder groove to fit the plywood based on thickness.

The side walls on the hutch part was grooved 1/2 depth and 1/2 straight bit was used. I used a portable router with the side guide. Before assembly you have to route and fix the plywood. Meron madali… Use a shoulder (basyada) 3/4 inch x 1/2 then sandwich the plywood by a moulding just like making glass frames..

-- Bert

View Muscle_x's profile


1 post in 2808 days

#5 posted 10-13-2010 09:13 AM

Great blog i read your all post here…i am really impressed reading your content…...


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