Shutter and Pallet Wood Cupboard - Part 2

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Blog entry by ~Julie~ posted 06-10-2011 02:19 AM 7665 reads 1 time favorited 8 comments Add to Favorites Watch

Continuing from yesterday Shutter and Pallet Wood Cupboard - Part 1

I’m going to dry fit the sides and back in order to measure for the shelf and bottom.

As you can see, this is like putting a puzzle together, it’s very creative and mathematically challenging, two things I enjoy!

I need to put dadoes in the sides and back where the middle shelf and bottom panel will be.

I am using my 3/8” diameter router bit and my router table. The middle shelf groove is about 12” down from the top, the bottom groove needs to be precisely made so that the bottom panel will meet the top of the bottom rail. (this will make more sense when you see the 3rd photo down)

Once all the dadoes are done the space has to be measured for the exact size of the bottom panel as well as the middle shelf. They both will fit into the dadoes as well as around the corners of the legs. Here is the bottom piece clamped in place:

You can see in the next photo how the bottom panel will fit up against the front bottom rail. There is a slight space there but once it is glued and clamped it will appear as if it is one continuous piece of wood from the back of the shelf to the front:

The middle shelf will come out to just behind where the shutter door will fit, that way when the door is closed the back of it will touch up against the middle shelf:

The only parts glued so far are the back panel glued to the back legs. Next I will have to think about making a top piece plus two top support pieces that sit in the dadoes at the top. The top will screw into those pieces from inside the cupboard.

I laid it on it’s back and glued the pieces together and clamped it up:

This is something you need more than two hands for as there are a lot of spots to glue and places to insert pieces and well… if you’ve done it before, you know what I mean, it can cause a polite girl to swear!

It definitely needs a lot of clamps with pressure at the right spots:

The top is simply made with three widths of pallet wood glued together.

I was going to paint the cupboard white, but I liked the grain on the legs and didn’t want to cover it. So, I coated the inside and out with clear shellac .I painted the shutter with Annie Sloan Chalk paint in the color “Provence” distressed it and then finished it with a coat of clear wax.

You can see holes from the previous use of the pallet wood, as well as different types of wood, although most looks like pine. There’s a wood toggle to keep the door closed in keeping with the simplicity of design.

It’s a one-of-a-kind piece.

-- ~Julie~

8 comments so far

View GaryL's profile


1099 posts in 3945 days

#1 posted 06-10-2011 02:40 AM

I have 14 shutters sitting in my shop that I just removed from a renovation project. They were going to be garage sale fodder but your project gives some food for thought.
Great re-use of materials. ( Do you need more shutters?

-- Gary; Marysville, MI...Involve your children in your projects as much as possible, the return is priceless.

View canadianchips's profile


2632 posts in 4112 days

#2 posted 06-10-2011 03:16 AM

Great little cupbard. Making use of used shutters. The dimensions are somewhat backwards from building a regular cabinet. EVERYTHING evolves around the door that is already made !

-- "My mission in life - make everyone smile !"

View sras's profile


6171 posts in 4244 days

#3 posted 06-10-2011 03:50 AM

I like the contrasting color of the door – very nice!

-- Steve - Impatience is Expensive

View hjt's profile


906 posts in 4253 days

#4 posted 06-10-2011 04:25 AM

As always, Julie – you have done a great job. So very talented!

-- Harold

View Maveric777's profile


2694 posts in 4191 days

#5 posted 06-10-2011 02:21 PM

Very cool and well executed…. I’m digging it…

-- Dan ~ Texarkana, Tx.

View chrisstef's profile


18133 posts in 4121 days

#6 posted 06-10-2011 05:10 PM

A new life for some old wood … well done and im sure that this piece will make it into someones home where they will be very happy with it. +1 for not buying materials .

-- Its not a crack, its a casting imperfection.

View Smitty_Cabinetshop's profile


17357 posts in 3733 days

#7 posted 06-11-2011 10:42 PM

Julie – Nice detail and great pics. Love the cupboard and the re-use of materials. Well done!

-- Don't anthropomorphize your handplanes. They hate it when you do that. - OldTools Archive -

View Vicki's profile


1170 posts in 4459 days

#8 posted 06-13-2011 05:58 PM

I like it. You did a first class, professional job. I was wondering how you were going to handle the color/shade difference between the shutter and case. You found the perfect solution.

-- Vicki on the Eastern Shore of MD

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