Studio711.com – Ben Martens

My woodshop is the third bay of our garage so I basically have one long wall to work with. It has always been a catch-all spot where I storage random sheets of plywood and generally dream of what might go there some day. It was time to stop dreaming and make use of it. I find that in my workshop I repeatedly get stuck in indecision. It’s silly because I will be making it all myself and I can just change it later if I decide I want to. Pick a path and go for it!

I saved some money by not building actual individual cabinets but rather each cabinet shares a wall with the one next to it. It was going to be a LOT of plywood, so I started by drawing the whole thing out in Sketchup, figuring out what pieces I’d need to cut and then I used a free cut list generator to help me optimize my plywood usage.

Part of the plan was to make a more permanent place for my miter saw to sit. The cart that I built in 2015 has been working great, but I’m tired of having it be in the way. With this new plan, the miter saw sits lower than the other cabinets so that wood rests flat across the saw onto the top of the cabinets. At some point I’ll put some T-track into the top of the cabinets to add a stop block with a tape measure for quick, accurate cuts on the miter saw. Normally you see these built with outfeed support on both sides, but I don’t have enough room for that. And while I’d prefer to have the outfeed support on the left side, this made more sense. The garage door is on the left so if I have to cut a really long piece, I can open up the door and get some extra room.

I used 3/4″ pine plywood (~$35/sheet at Home Depot). I’ve used that for most of my shop projects and I’m always impressed at how nice it is for the price. The tops of the cabinets got two sheets of the plywood. It adds a bit of cost but it really strengthens the top and makes the cabinets feel more solid.

The first step was cutting each of the vertical pieces. These were basically just rectangles with a notch cut out for a toe kick, but there were two complications. First of all, I had to cut out a notch for the foundation wall. Secondly, the garage floor isn’t level. I wanted to spend a little extra time to make the top work surface be level to avoid hassle with the drawers later. So each of the vertical pieces was going to be a slightly different height. Instead of trying to get that perfect, I left each one about an inch short. Then when it came time to mount them in place, I would hold them at the right height, slide a piece of scrap plywood up next to the bottom and screw the scrap into the vertical divider. So the cabinets are screwed into the studs and then rest on the floor.

I don’t know if I’d do it this way again or not, but to space out the vertical dividers, I cut a bunch of pieces the with of the cabinet and pocket holed them into the dividers. On the plus side, it made it easy to assemble each section one by one and keep them all evenly spaced, but on the down side, it was a lot of screwing and cutting.

You’ll see that not every opening is the same width. I went with 3″ multiples since that’s what normal cabinets use, but I tried to add in some variety for storing different things.

After adding the top (YAY! Finally a place to put some tools!), I ripped down some 2x4s to make a face frame. Hiding the plywood edges looks nice but it also helped me make perfectly rectangular openings which pays dividends down the road when it’s time for drawers. The laser level was instrumental in getting the top of the cabinets level and also at this point in the process when I was making the dividers perfectly vertical and the horizontal face frames perfectly flat.

Now it was time to make the drawers. A LOT of drawers. 20 to be exact. Again, I probably could have gone an easier route, but I chose to assemble the drawers by using dadoes. This gives a bit of additional glue surface and helps to keep things square during assembly. Unfortunately my little shop vac can’t handle the dust collection duties for dadoes so it repeatedly slogged up the hose inside my table saw. I finally just gave up on dust collection with the dadoes, disconnected everything, and cleaned up afterwards.

Most of the drawer sizes were pretty standard, but there were two special ones. One of them is full height and my plan is to use that for scrap hardwood storage. I have a bunch of smallish pieces and I had previously been standing them up in a trash can. The other one holds my planer. That planer is pretty heavy so I ended up using a double set of drawer slides which seems to be working well so far. If it starts to sag I can always kick a block under the end of the extended drawer when I’m using the planer. I don’t know how well both of these special drawers will work in the long run, but it’s easy enough to take them out and add standard drawers later.

Speaking of drawer slides, that part of the project can really break the bank. I have bought some very cheap slides from Amazon in the past and had good success so I went that route again. This time I got Promark full extension slides along with some mounting screws.

After the above photo, I finished off the last six drawers and now it’s fully functional. I moved on to some other projects, but soon I will add drawer fronts. Those will help to hide the uneven spacing of the actual drawers and bring them up flush with the face frames. I’m planning to design and cut some drawer pulls on my new CNC machine as well.

This was a huge project and it was a pain breaking down 13 sheets of plywood, but man I’m loving it! I have a huge new work surface and so much storage. Building drawers takes a lot of extra time and money, but I find that they are a lot better than deep shelves because you can actually use the whole depth instead of forgetting what’s behind the first row of stuff.

Elijah came in at the end of this post and wanted to help so I’ll close out with his thoughts. “I just really like those cabinets. I love them. I just really love those cabinets. They’re so great. They’re just so great. That’s all.”

I’ve made a project in the woodshop every year of Elijah’s life. That’s kind of a hard trend to break. The first year was a table and chairs and ever since then, I’ve made something from the Wood Magazine construction sets (end loader, dump truck, semi lowboy and dump trailer). I stuck with that theme this year and made the skid steer. I was crunched for time and it was a small project so it seemed like a good fit. Thanks to Tim for giving me some scrap maple so I didn’t have to make a run to the lumber store. Follow him on Instagram under the @woodscreekwoodworks account.

The project went pretty smoothly, but, again, I felt like the instructions could have been better. There was too much precise cutting and hoping that stuff lined up later. Why not just leave it all a little long and then flush it up later? I need to get better at building stuff in my head to recognize these opportunities.

I bought the kit that provided all the hardware and wheels and it came together pretty quickly. With these toys, I’ve learned to mill up lots of extra wood so that I can have another crack at it when things go wrong and that skill proved useful here.

Some day I won’t be able to post this stuff early, but for now, Elijah doesn’t read my blog so I can show you a picture early. Merry Christmas!

Tim and Chelsea’s daughter had her first birthday and Tyla had the idea of a wooden name puzzle. I decided to give it a shot. I found a font that I liked, printed out her name and then used spray glue to stick it to a piece of pine. That was cut out on the bandsaw and sanded. For the paint, I went with a spray enamel which I hadn’t used before. It worked well but the weather was cool and rainy so it was hard to get the coats to pile up. In the end I left it with the top looking great and the other sides looking passable. For the bottom, I grabbed a scrap of sapele and routered out space around the letters. It might be a bit too challenging of a gift for her to do at this point but it was fun to make and she seemed to enjoy moving the pieces around.

When we visited Grandma Martens this summer, she showed us a photo album of a bunch of Grandpa’s woodworking projects. I thought that was a pretty neat idea, and while I’ve blogged about most of them, I thought I’d walk around the house and make a video of my projects. I realize it’s dorky, but what did you expect from me?

A couple years ago, David Picciuto made a Super Mario picture using 1″ square “pixels” cut out of three types of wood. That has stuck in my head as a fun idea and it ended up being the first project that I completed since April. (My shop has been used for storage during the siding and window project on our house.)

I chose maple, walnut and paduk for the white, brown and red pieces. The key to this project is getting all ~150 squares to be totally identical in size so that when you build them into Mario, the lines stay straight. The next trick was getting a chamfer cut on all four sides of the squares. This helps to define the edges and made each square look more like a pixel. I cut two of the sides with a router when the wood was still in 1″ strips. After cross cutting those strips into squares, I set the table on my small disc sander to a 45 degree angle and sanded the rest. Then I had to hand sand each square to clean them up.

David put his on to a square piece of plywood and made a frame for it, but I wanted to make mine frameless. I cut out a piece of plywood on the bandsaw that would be just smaller than the assembled Mario. I picked a row near the center and carefully glued it as straight as I could. From there I glued two or three rows at a time working out toward the top and bottom. I took my time and let the various rows dry before getting too far so that I could make sure I was staying straight.

I love this project! Thank you David for the inspiration!

In August of 2016, Logan and I took down the two dying trees that were along our driveway. I saved a few pieces of the wood and attempted to cut them into tiny slabs. There’s an old saying that goes something like “logs rot and lumber dries.” Yes, you can leave a log to sit there and dry completely, but it’s better if you can cut it into very rough sizes and stack it up with room for air to move between all the pieces. It will drive more evenly with less cracking.

I finally pulled it out of the shed a couple weeks ago and stared at it … it wasn’t particularly beautiful cherry, but it seemed fun to use it for a small project. I remember Grandpa Martens making crosses out of the tree they took down in his front yard so I set off to make a cross as well.

The design emerged from some trial and error, but I ended up building a cross with 45 degree miters to fit all the pieces together. Then I sawed it in half in both directions to end up with 4 L shapes. I cut a rabbet into all of the interior sides and inlaid a piece of paduk, leaving the cherry a bit longer than the paduk. It was a tricky glue up but it held together. I finished it off with a couple coats of shellac. I think it will look a bit better as the cherry oxidizes and darkens over time.

I’ve been working with maple for a couple years, but I’ve never used “curly maple” before. The Wood Database describes it as a maple board where “the ripples in the grain pattern create a three dimensional effect that appears as if the grain has ‘curled’ along the length of the board.”

It’s generally expensive to buy since it’s somewhat rare, but Crosscut Hardwoods in Seattle had a stack of ~30inch long boards that had some curl in them. I picked up two of them to play with and I ended up attempt a small box.

You’d think that a small box would be simple, but it seems like the smaller your project is, the tougher it is to get it right. Tiny gaps and imperfections are a lot more noticeable on small projects.

The first thing was deciding what size box to make. Based on the wood I had available, I went with 3″x5″x8″. Fun fact, if you want a box to look “normal”, use the Fibonacci sequence to determine your dimensions. It’s a close approximation for the golden ratio of 1:1.61803399. Fun fact #2, if you follow that rule, your box will have the same ratio between the dimensions as the Parthenon.

Jointing and planing the curly maple was a challenge. Even though I had recently replaced the blades on both machines, that curly grain is extremely subject to tear out. I took very light passes and did a lot of sanding. A drum sander would have come in very handy to make all the pieces a uniform thickness without tear out.

For the box construction, I mitered the four sides at 45 degrees on each end and then created a dado for both the top and the bottom panel. I glued it all together and ended up with a box that had 6 sides and no way to open. Then I moved over to the table saw and sawed it in half, being careful to insert spacers into the kerf that I had just cut so the box wouldn’t pinch the blade and eat me.

There are multiple methods for creating a snug-fitting lid. I chose to line the inside with walnut and leave the sides of the walnut a little taller than the interior of the box. With a little sanding and finessing, the top fits perfectly over that interior lining. I finished the whole thing off with a couple coats of shellac.

I learned a lot making it which is code for “I made a lot of mistakes, some of which I couldn’t recover from”, but I think this one will be good enough to sit on my dresser without annoying me. The grain is beautiful when you hold it up to the light and see how it changes. The pictures don’t do it justice.

Frank Howarth got involved in an auction at his kids school again this year and made an incredible neighborhood art project. He started by cutting up a bunch of scraps and having he kids put them together to form pictures of their houses. Then he combined all the houses into a single neighborhood on a piece of wood.

As I was out in the garage with Elijah a couple weekends ago, I thought he might like giving something like that a try. I cut up various pieces from some nice scraps and asked him to make a house. That proved to be a little challenging so we switched to robots. He was immediately on top of that and made two of them almost completely by himself. At that point we ran out of the scraps that I had cut and he ran out of patience so we called it quits.

Later, I took a picture of what he had made and then transferred it onto a square piece of cherry plywood. I made a simple frame out of some walnut scraps and voila! I’m excited to get this finished and hung on his wall. I’m waiting for the weather to warm up a bit so that I can put some finish on it.