Shop Storage Solutions #5: Sides are 1/2 way done

  • Advertise with us
Blog entry by HokieMojo posted 08-15-2009 10:41 PM 7049 reads 0 times favorited 6 comments Add to Favorites Watch
« Part 4: Lots of Work - Minimal Results Part 5 of Shop Storage Solutions series Part 6: Now it looks like a lumber rack »

First off, I’m amazed by people that crank out quality projects. This construction grade project has been slow going and there really isn’t too much detail. The heat is also really wearing on me so I only did about 4 hrs today. I doubt it looks like 4 hours of work, but lots of predrilling and lots of screws.

I started off with the objective of finishing the base. I needed to complete the floor for the plywood storage and attach the wheels. The shelf floor went on just fine. The wheels weren’t quite as easy. Here is a picture after getting the wheels on.

The problem with the wheels was that I assumed the stems would be long enough to go through the plywood wheel supports. I used doubled up 3/4” ply. As you can see, they weren’t long enough.

What I did was I drilled a hole with a spade bit into the top of the supports. It was just large enough to get a washer into the hole (1” wide maybe). I drilled through three layers of ply. This worked well because as I went through each layer I could see the black glue. It made for the easiest measuring of the project so far. I then finished with a 3/8’s bit all the way through. I don’t know if this will weaken the structure. personally, I don’t think so, but we’ll see.

The other mistake I made was I had already attached the wheel supports thinking I could just slide my ratchet in there. I needed to disassemble everything and then put it back together. up to this point i probably spent 1.5 hrs btu at least 15 minutes was kicking myself for not realizing my mistake. all in all though, not a big deal.

On to the sides!

I left the base with a 19.5 gap between the floor of the plywood and the floor for the offcuts. after subtracting 1.5 inches for the plywood thickness, that leaves 18 inches at the base. the sides are 42 inched high. I’ll put a shelf ever 13 inches. this means that every 13 inches, the sides will slant one inch inward (on each side) I think that will be plenty to keep material leaning but not so much that it causes additional downward stress.

I measured each 13” increment and marked up the plywood. here are 4 shots (2 of each side) of the cleats being glued into place and screwed in, mostly to pull the parts tight during gluing. I was shocked that I used as many screws and as much glue as I did. I’ve already used a whole small bottle and a whole box of screws (although they were varied sizes).

I was careful to try and keep the bow in the plywood pieces going the opposite direction of one another. I don’t think it will make a significant difference, but every little bit will help. Screwing the shelving in will really line everything up and make it much more rigid.

I’m actually really pleased with the progress. I think tomorrow I’m going to take a day off and just rest up. Then on Monday I’ll try and finish this thing off. I’ll need to rip the shelves to their final width and figure out a way to hold up the sides while I work on getting the parts in place. I’ll also need to screw the sides to the base. If that gets done in less than 2 hrs, I might start on the dividers for the cutoff bins.

One final note, thanks to everyone for their advice on the casters. I was using the base as my workbench and I locked the casters. They didn’t go anywhere. once I was done, I put the last piece of plywood on it to simulate the weight of the structure (unloaded). After unlocking them I could easily move it with one hand. So far, I’m thrilled. I hope they work as well when I put another 700 lbs on it.

One FINAL FINAL note. here is a shot of the scrap pile. If not for the mdf, that was already scrap, I’d be at virtually 0 (1’ x 6” plus sawdust). I’m not soing this just to do it, I’m just trying to keep costs down after my wife has been so good about saving money recently. I may use some of the mdf scrap anyway when making some of the clamp rack attachments, but I’ll decide all of that stuff at a later date.

6 comments so far

View a1Jim's profile


117159 posts in 3628 days

#1 posted 08-15-2009 11:47 PM

Wow at first I thought you were making a giant skateboard. good work

-- wood crafting & woodworking classes

View HokieMojo's profile


2104 posts in 3779 days

#2 posted 08-16-2009 10:00 PM

just what I’d need, another way to hurt myself.

View PurpLev's profile


8539 posts in 3699 days

#3 posted 08-16-2009 10:11 PM

this is turning into a behemoth! nice progress

-- ㊍ When in doubt - There is no doubt - Go the safer route.

View HokieMojo's profile


2104 posts in 3779 days

#4 posted 08-17-2009 12:26 AM

It is big. I’m a little worried about how much weight these casters will be able to take. I’ll adjust accordingly, but I’m hopeing they can hold about 1000 lbs. I think the project itself may be around 200lbs alone. once I add 7-8 sheets of 3/4 ply, drywall, or mdf thats a lot. the lumber storage, I can’t even guess atthe wieght. Then the pipe clamps will be quite heavy on the otehr side. I guess I’ll just load it till it becomes awkward to push or it starts to make creaking noises. lol.

Tomorrow it should really start to take shape.maybe people will be able to tell what it is supposed to look like.

View Joe Lyddon's profile

Joe Lyddon

10147 posts in 4103 days

#5 posted 08-17-2009 01:02 AM

I was wondering you might need two more casters in the middle!

Think so? Looks awefully heavy…

Looking fwd to seeing progress…

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: ... My Small Gallery:"

View HokieMojo's profile


2104 posts in 3779 days

#6 posted 08-17-2009 03:20 PM

i guess i can always go back and add some. I had thought about trying 6, but I’ve been told it often causes more problems than it helps. If anyone else has thoughts on this, I’d appreciate hearing them.

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics