Shop Storage Solutions #6: Now it looks like a lumber rack

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Blog entry by HokieMojo posted 08-18-2009 05:37 AM 8254 reads 9 times favorited 14 comments Add to Favorites Watch
« Part 5: Sides are 1/2 way done Part 6 of Shop Storage Solutions series Part 7: A final descision on the sheet goods storage »

Well, I’ve got some bad news for the 3-4 people reading my blog. This is going to be the last post for a while. I was hoping to finish everything during my vacation, but it won’t be done in time and I’ve got a few other things I need to do over the next few weeks.

The good news is that I’m just about done. The last few steps will be kind of time consuming with minimal results, so I don’t think anyone will be dying to see the next few posts. I will blog them when I do them though, I just don’t know when it will be. I’d really like to get a parking space back for my wife and that requires some serious cleanup. Here are the pictures for today though. Sorry again to those who have been keeping up. Before I get into the build, heere is a sneak peak at the results.





That’s just pressure treated junk. i don’t want it with the good stuff, so it doesn’t count.



I know, the last photos are the same in the before and after. I told you I didn’t finish! So, you thought you’d get a sneak preview of the project? nope. keep reading for those pictures.

I didn’t get a shot of me ripping the shelves to length, but basically they are 12, 14, and 16 inches wide by 7 ft long. It was the last piece of large plywood I had left. once they were ripped, the trick was to get them into place. I was basically leaning the two sides against one another, then prying them apart to try and slide shelves in between. At one point, I had all the shelves resting on the cleats, but the assembly wouldn’t stay balanced and upright. I was stuck…. Literally….

Thankfully, after me standing there holding them for about 15 minutes my wife came down to ask me something and I jumped at the chance for a hand. She kept it balanced while I clamped everything up. Then I just snapped some chalk lines where the shelves would be and started predrilling holes every 8 inches. I applied some glue and also used 2.25 inch coarse thread screws to pull everything tight. Here is a shot of me about to screw in the last shelf. It was in so tight after attaching the top two shelves that I didn’t bother to glue it. I hope I don’t’ regret it.

You can see the screws sticking out. I gotta say, this is one more time where my corded dewalt drill really came through for me. I have abused that thing so badly over the years, and it still runs like a champ. normally, it is one of my most under appreciated tools, but projects like this remind me what a solid piece of machinery it is.

Once all the screws were in place it was time to start loading it up. First, here is a shot to give you an idea of how much storage is in here.

Time to start loading up the plywood. I think that will be a good test since it will put a lot of weight on the assembly without stressing the shelves. here is a shot of the plywood in place (and some scraps of pegboard and drywall).

I’d estimate there are about 500 sq feet of sheet goods on there. Probably 200 of 3/4”, 50 of 1/2” and the rest 1/4”. I think that works out to about 250 board feet of wood right there. So far so good. It isn’t making any noises or flexing and I can still easily move it with one hand.

I guess its time to start adding lumber. Now or never right? I’ll admit I was nervous. Here are hose shots.

As you can see in the last photo, there is nothing on the one side of the project. I’ve still got the material to cut dividers and the pegboard you saw earlier will be used as a wall to hold it all in. I’m hoping it allows me to hang a few small clamps from it, but I don’t know if that is a great storage location. they may get knocked off too easily.

Another change I plan to make is that I don’t plan on having the cutoff bins go all the way across. I think they will sit in the middle and I’ll have clamp storage on the flanks. maybe it will be vise versa. Any suggestions? Thanks to everyone for sticking with me this far. I will do more, I just work rather slowly.

PS – When I loaded all the lumber, I must have hit a tipping point. It suddenly became MUCH harder to move. I can still move it with one hand, but guiding it requires both and some effort. I am going to try and use up some of this material I’ve got before buying any more for a while. That is the plan at least. This thing probably weighs about 800 lbs right now. If that’s accurate (just based on board foot calculations and my 35 lbs per 1/2 thick sheetgoods assumption) I could probably go to 1,000 lbs without problems. I’d like to get more wight moved to the bottom but I have a few more screws to drive down there.

14 comments so far

View Karson's profile


35125 posts in 4423 days

#1 posted 08-18-2009 05:56 AM

A great way to put your materials in an easy to use space.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View oldwoodman's profile


137 posts in 3421 days

#2 posted 08-18-2009 05:56 AM


You have built a very nice storage unit. Your design is straightforward and evidently quite strong. You certainly have loaded a lot of wood onto that thing!! Great job!

View patron's profile


13606 posts in 3364 days

#3 posted 08-18-2009 06:34 AM

looks real nice ,
and an interesting read .
looks like a great storage .
maybe some handles through
bolted at each end would
help with moving it ,
at least that’s how it works for carts and trailers ?

that walnut sure would look good in my rack ,
if it gets to heavy !

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View Trikzter's profile


42 posts in 3279 days

#4 posted 08-18-2009 07:54 AM

Very nice design and idea.
Although the misses was looking as I was reading and looking at the pictures, so now guess what? Yep she says I need to make one. sigh….

-- Rick... A tree knows more about wood then I do.

View Mike Gager's profile

Mike Gager

665 posts in 3290 days

#5 posted 08-18-2009 01:33 PM

i saw this same storage thing in a magazine recently and thought it would be a cool way to store lumber.

as for your problem of it being hard to move, what are your casters rated for? they may just be to small for that amount of weight

View woodisit's profile


61 posts in 3265 days

#6 posted 08-18-2009 04:06 PM

Looks good, if you can’t go to larger casters you might add a set in the center to distribute the weight more.

-- Woodisit

View Todd A. Clippinger's profile

Todd A. Clippinger

8901 posts in 4122 days

#7 posted 08-18-2009 04:08 PM

Organizational projects are fun to build and they do wonders for the shop space.

-- Todd A. Clippinger, Montana,

View Doug's profile


43 posts in 3331 days

#8 posted 08-18-2009 05:43 PM

Looks Good Man,,,,,, I’ll give you 50 cents for that walnut, but you gotta deliver it . LOL. Great job guy !

-- Use your imagination ! you'll be suprised

View sIKE's profile


1271 posts in 3777 days

#9 posted 08-18-2009 06:03 PM

Yeah you probably hit the recommended(not the max) load limit of the casters. Next size up would probably restore the ease of movement that you lost. The cart looks great! You are going to make use of it for a long time! Can’t wait to see the finish project!

Do you want to store more clamps or shorts? Make the call and then make the placement to meet your needs. I know pragmatic but it is what it is….

-- //FC - Round Rock, TX - "Experience is what you get just after you need it"

View ellen35's profile


2738 posts in 3455 days

#10 posted 08-18-2009 06:07 PM

Wow! Very impressive piece of work!
Looks like it will be really useful.

-- "Don't let the perfect be the enemy of the good." Voltaire

View jockmike2's profile


10635 posts in 4269 days

#11 posted 08-18-2009 06:27 PM


-- (You just have to please the man in the Mirror) Mike from Michigan -

View GMman's profile


3902 posts in 3720 days

#12 posted 03-01-2010 02:58 PM

Great job I like the storage unit very good idea.

View Beginningwoodworker's profile


13345 posts in 3696 days

#13 posted 01-27-2011 04:48 AM

Thats a neat idea.

View RSQMonkey's profile


3 posts in 428 days

#14 posted 04-19-2017 10:43 PM

What was the frame width? 7’ x 36”?

-- Professional Woodworking Student

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