WHAT IT TAKES
Time: 1 weekend
Skill level: Beginner
WHAT IT TAKES
Time: 1 weekend
Skill level: Beginner
These easy-to-build boxes suit any situation. They’re easy to build, easy to customize and a money-saver besides.
Materials for the boxes shown cost about $250, with $50 for closet hardware. The 3/4-in. birch plywood is strong and thick enough to accept screws. It also finishes well, and the simple grain and warm color look good with just about any décor.
A 4 x 8-ft. sheet costs $45 to $50. Here’s a rule of thumb for estimating the plywood you’ll need: One sheet will get you two large boxes or four small boxes, plus some leftover parts. If you don’t have a pickup, have the plywood ripped into roughly 16-in.-wide pieces at the home center and then rip it to 15 in. at home.
Before you start cutting up box parts, check the thickness of your plywood. Most “3/4-in.” plywood is actually 23/32 in. thick, and the measurements given here are based on that. If your plywood is thicker or thinner, you’ll have to adjust your box part sizes. The measurements given also account for the typical thickness of iron-on edge band.
To make this closet system work, you need to cut lots of box parts to exact, identical lengths. This plywood jig makes that foolproof. Build the jig and you’ll find lots of other uses for it. You can use it to build bookcases, cabinets or shelves.
If your saw is out of whack, you won’t get accurate cuts. So do a quick inspection: Measure from the front and back of the blade to the edge of the saw’s shoe to make sure the blade runs parallel to the shoe. Then grab a square and make sure the blade is set at 90 degrees to the shoe. Install a 40-tooth carbide blade for clean cuts.
Take your time when you build and install the carriage assembly. First, screw the guide to the carriage. Then run your saw along the guide; that will trim the carriage to suit your saw. When you mount the carriage on the rails, use a framing square to make sure the carriage is perfectly perpendicular to the rails. You can add a stick-on measuring tape to your jig. One last note: Be sure to set the saw depth so it just grazes the jig’s base. If you set the saw too deep, you’ll cut your new jig in half.
If you haven’t edge-banded plywood before (Photo 2), don’t be intimidated; it’s a skill you can master in a few minutes. You could glue and screw the boxes together, but you can use biscuits to avoid exposed screw heads (Photo 3). For more on using a biscuit joiner, go to familyhandyman.com and search for “biscuit.” Clamp each box together (Photo 4) with a clamp at each corner and check the box with a framing square. It should automatically square itself if you’ve made accurate square cuts. Let the glue set for an hour before removing the clamps.
Finishing the boxes could be frustrating: Birch tends to get blotchy when stained, and brushing on a clear finish inside boxes is slow, fussy work. Sidestep both problems by applying two coats of golden oak penetrating oil finish. It leaves only a light film on the surface, so you don’t have to worry about brush marks. And the light color minimizes blotching. Wipe-on poly would work well too. Use a brush to apply either finish and then wipe it with a lint-free cloth.
Once the finish is dry, join the boxes together (Photo 5). Sleeve connectors (see the Materials list) look a lot better than exposed screws. Just remember to use a Pozidriv screw tip to tighten the connectors. It may look like a Phillips, but it’s slightly different. Pozidriv screw tips are available at home centers and hardware stores. You’ll also need a 3/16-in. or 5mm drill bit.
To simplify mounting the boxes to the closet wall, install a cleat (Photo 6) on the wall studs about 8 in. from the floor. The 8-in. elevation keeps the boxes off the floor and provides usable space below. Make the support from long plywood scraps. The elevated ledge will support the assemblies while you get them placed and then screwed to the wall studs. Drive 2-1/2-in. screws through the box backs and the studs. If a box doesn’t land on studs, use screw-in drywall anchors.
Once you have all the boxes secured to the wall, you can add closet rods (centered about 11-1/2 in. from the back wall) and other organizers like tie racks and belt hangers and screw them directly into the 3/4-in. plywood construction.
Not just for closets!