I had mentioned earlier on a thread that I had to build some outdoor cabinetry going on a deck on top of a boathouse on a mountain lake, the same one we have a home on. I had a few contact me and asked me would I do a show and tell on it. I don’t really have the time so I’ll just offer as much as I can when I can with pictures.
This set of cabinets is going in the corner of the covered part of the deck. It has a culprit from the git go and that is a post in the corner about 2 feet from the deck rail. A corner cabinet will go up against the post and will hold a 60 inch big screen tv with an automatic remote control vertical lift. The back side of the cabinet is about 76 inches long and the front is about 46 inches.
To make everything work with the left side and right side base cabinets and fit close to the rails, per client request, the corner cabinet worked out about 15 inches deep front to back, the sides will be standard 24 inches. The base cabinets will be the standard 24 inches wide and 36 inches high including a 2 inch thick wood top. The left side base cabinets will be for storage and is 91 inches long. The right side base cabinets will hold a YETI cooler. The countertop will be made to lift up and when it does the top of the YETI cooler will lift with it. At the end of this cabinet will be 45 degrees with a center and bottom shelf.
The cabinets are being built out of clear and better 4/4 and 5/4 Cypress. The inner panels that can’t bee seen will be built out of MDO primed and painted. 3/4 inch for the panels and 1/2 inch thick for the floors. The countertop will be 12/4 clear and better Cypress using 6 inch wide boards. I have 300 brd feet of the 4/4 and 100 brd feet of the 5/4 clear and better Cypress. For the top I have 18 12/4 clear and better Cyrpess boards. The color going on all the Cypress is a Cabot Heartwood exterior stain sprayed one coat. No sealer.
My small shop is near this lake so I’ll build the cabinets there and not in our millwork shop. When I get the tops glued up I’ll carry those to the bigger shop and run them through a widebelt sander to flatten them. My Performax 22-44 will definitely not handle that much weight and would take forever to sand it if it could. All the end panels, doors and face frames will be sanded on my Performax. I’ll carry the long rear panels and run them through a widebelt also.
Construction of the cabinets will be mortise and tenon face frames to the side panels.
I’m using an 80 tooth TCG (triple chip grind) Freud saw blade to cut the MDO and a 60 tooth TCG Freud bade to machine the Cypress with. I use these same blades to cut plywood, Corian and Melamine with.
I’ll try to put up more pictures and more info on the build later this week. If anyone has any questions I’ll try to answer them. And thank you.
-- Bruce Free Plans http://plans.sawmillvalley.org