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5,163 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
I agree with Sharon about the blog. It works fine if it is broken up with pictures, as you have done.

One comment I would suggest is to use locking swivel casters for all of your wheels. The fixed casters will only move in one direction. I used them on my mobile miter saw stand and it is a challenge to change direction with the cart.
 

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9,309 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
onwards and upwards ,
good blog .

yes on all swivels .
 

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1,699 Posts
Discussion Starter · #23 ·
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
Thanks for the encouragement. It is good to know someone gets something from this. I know that personally, I've grown to enjoy reading the blogs more than the project postings. Blogs are always almost always more original than the projects. I still enjoy the projects, but they have become a bit repetivie now that the site has grown so large.

I'll take your advice on the casters and go with all 4 locking swivels. I was thinking a wider mounting plate might make the black casters better, but I can se what you mean and will go with red.
 

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Registered
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930 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
Your blogs are well written and easy to follow. Keep it up. Yes go with the red casters. You will find that the black ones are hard and don't roll very well once you have added some weight, which is your plan for this beastie. Looking forward to the next post.
 

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19,680 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
good progress
 

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Registered
Joined
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1,624 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
Your blogs look good as everyone else has said. Your progress is just fine. Keep up the posts and continue on. Keep on making sawdust.
 
Joined
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4,013 Posts
Lots of Work - Minimal Results

Before I start, if anyone has any suggestions to make my blog more readable, please let me know. I spend about an hour on each entry and I still feel that they are severely lacking. I can't do much about the topics since I only blog what I'm working on. I try to include photos too. I may be a bit long winded though. Any criticism would REALLY be appreciated.

I debated whether to post today because it doesn't look like I did much, although I think I did lots with few visual results. I committed to blogging this project through to the end since I think I can finish it on my week off, so I guess I should do it right. I should take one moment to say that my wife has been very good about taking care of our daughter during the day so I can work on this, but there is one catch. My daughter's playpen shares a wall with the garage. We are also trying to get her used to afternoon naps, so anytime it looks like she might zonk out, power tools have to go off. Inevitably she is ready to sleep anytime I finish laying out my cuts and have just put on my safety equipment. I spent 5 hrs working today, but probably could have done this in 3-4 if I was on my own schedule.

In the morning I ran some errands and one of those errands was to get 3" screws. That allowed me to firm up the base that I had just nailed together the prior day. I decided diagnal bracing with 2×4's wasn't necessary because of a couple design modifications (covered later).

Now that the base was nailed and screwed, I needed to add my wheel supports. These came from a 1'x4' piece. Here is is marked for cutting. Hopefully you can see the 8 triangles.


After cutting them I tried to double them up with glue. I know the clamping pressure is not sufiicient for that much surface area. I thought it would make it easier to assemble everything, but changed my mind after the first two.




Now I've got somewhere to attach the wheels once I decide which to use. Here is what I've got

4 of these:


or two of each of these:


I've still got a day to think about the wheel choices. Now I flip over the base so it is right side up and start working my way upward. Here is the first change I made. I realized that while my design modifications would be fine for long lumber storage, I kind of need a floor to support the upright shorts. So, I'm swapping out a 2×4 from the original plans with a 1×6 to be used later. Now, the 2 pieces of 4'x6" plywood I cut yesterday are going to become part of the base. Here you can see it glued up. IT will serve as a floor for the cutoffs and will give an edge for the "A-frame" type structure to push against.


I also decided I'm going to use some scrap shelving to make a floor for the plywood. I'm certain that I could store the plywood across the exposed 2×4's but it might do some damage to the edges, particularly when trying to load and unload the 3/4" pieces. This is my 3rd cheat (1st was using old pegboard, 2nd was swapping out a 2×4 for a 1×6 (although the 1×6 was even cheaper)).

Now I need to start in on some of these large sides. I layed out the windows on the plywood support side. I plunge cut with the circular saw. This did scare me a bit because it feels like I'm cutting on a table saw without a fence or miter gauge. I'm not sure what the difference is except for maybe h.p.m but I guess it worked fine. here are the pictures




Once all is done, it looks like this:



So here is what I still need to do.
1 attach wheels
2 Attach the MDF to the base for the plywood storage side.
3 Attach the cleats
4 Cut the shelves to width and angle the edges to match the slant of the sides (the sides will be 18" apart at the base, with 3 subsequent shelves being 16", 14", and 12".
5 Attach the shelves
6 layout the dividers (unless you guys think my plunge cuts came out perfectly straight)
7 attach dividers
8 attach the front of the cut-off bin
Great progress.
 

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1,699 Posts
Discussion Starter · #28 ·
Sides are 1/2 way done

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.

 

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Sides are 1/2 way done

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.

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

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Discussion Starter · #30 ·
Sides are 1/2 way done

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.

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

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Sides are 1/2 way done

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.

this is turning into a behemoth! nice progress
 

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Discussion Starter · #32 ·
Sides are 1/2 way done

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.

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.
 

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Sides are 1/2 way done

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.

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

Think so? Looks awefully heavy…

Looking fwd to seeing progress…
 

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Discussion Starter · #34 ·
Sides are 1/2 way done

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.

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.
 

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Discussion Starter · #35 ·
Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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.
 

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Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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

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Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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.
HokieMojo,

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!
 

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Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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.
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 !
 

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Registered
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Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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.
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….
 

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335 Posts
Now it looks like a lumber rack

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.

Before:


After:


Before:


After:

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

Before:


After:


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.
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
 
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