cutting list and assembly diagram [pdf] - Home-Dzine

workshopfoldawaybenchCompact workspace that tucksneatly into a storage unitWords David Radtke Edited by Frank GardnerWhen closed, thisbench tucks into awall-mounted unit and,when open, it providesa 1200 x 900mm worktop. There isaccess to tools from shelves on bothsides and a double-sided pegboarddoor. To set it up, just pull the legsfrom the recesses under the top andsecure with four steel braces andthreaded knobs. Then release thebolt latch and lower the bench.FINISHING When the unit and benchare complete, mount a bolt latch tothe centre face frame piece. (Ensure itfits down through the front apron atleast 25mm.) Mount the latch so thatwhen raised, the bolt sits about 2mmabove the lower edge of the lowerface frame. Drill pilot holes and screwit into place. Drill another hole inthe front apron of the worktop tomate with the bolt on the latch.Hold the worktop closed andunbolt the latch. Lower the worktoponto the floor and then drill a 12mmhole for the bolt. Finish with twocoats of polyurethane. When thefinish is dry, install the shelves.Position the base of the uniton the wall at the heightyou want the table to be.ab3mmsetbackctopsidecentree1middlepartitionfe2fnail e1here300mm speedsquaredhangerstripbbacka915mm tobottomof sidee2top34215 67810Skill ratingCostDo it yourself1 day $360Have it done934215 678109Sweat rating1Compile the componentsCut the 19mm plywoodaccording to the Cutting List.Use a straightedge guide or table saw tocut pieces to width, then a large squareas a guide to cut them to length.TIP A speed square helps make90º crosscuts.2Assemble the cabinetGlue and nail side pieces to thetop and bottom with 50mmbullet head nails every 150mm. Glueand nail the front hanger strip to thebottom and sides. Recess the hangerstrip 3mm to make room for hinges.Fix back (D) in position every 150mm.3Add the partitionsStart by centring the middlepartition. Glue and nail it tothe top, bottom and through theback. Then glue and nail the fixedhorizontal shelves into place. Skewnailthe second (E2). Fix face framepieces (F and G) in place.6 hours $60092 SEPTEMBER 2007 Handyman Handyman SEPTEMBER 200793

25mmfromback30mmfromfront6mm bradpoint bitpegboarddrill guidestrip4Drill shelf pin holesCut a strip of pegboard to useas a drill guide for making the5mm diameter, 12mm deep shelfpin holes. Use a stop on the bit toprevent it from punching throughthe opposite side. Finish the holes175mm from the top and bottom.steel supports75mmfrombackholes19mmfrombacklside apronkjworktop5Fix the apronsGlue and nail the side and frontaprons to the worktop, makingsure they’re flush withthe top. The apron helps keep theworktop flat.kfrontapronlfront1mm gapnmstrutlegm8x50mmcupheadbolt6Curve the leg endsJigsaw a 35mm radius on eachleg top. Drill through the sideinto each leg. Position a cuphead boltwith an extra washer between the legand side apron. Nip the nut but don’ttighten. Glue and nail strut to frontand back aprons (see Diagram 1).35mm rad.8mm hole6mm holem65mm35mm5mmhole460mm8mm holegrind orfile radiusppflush f withe2 on bottom70mm hingesu154mm setback3mm setback85mm butt hingesgafjchte1rnsfqdlge2bu2amagneticcatch5mm shelfsupportsm6x40cupheadbolt15mmhex headscrewn355mm65mm7Attach steel supportsCut the 460mm steel supportsfrom 19 x 3mm steel. Round theedges with a file or grinder, then drillholes as shown in Diagram 1. Attachthe supports to the strut and the frontapron, making sure the leg is squareto the apron both ways.kbackapronl85mmbutthinge90mm8Fix the hingesTo finish the worktopassembly, screw three doorhinges to the back apron, aligningthe barrel of the hinge with theedge of the back apron as shown.25x1.8mmnailsrsssupportrail9Prepare the pegboard doorGlue and nail the door stilesand rails to the front and backpieces of pegboard. When the glue isset, install the hinges on the pegboardand mounting strip (see Step 10).rqapplygluesupportstile12mm hole(align with boltlatch and drillthrough)15mmscrewsmlDIAGRAM 1Foldaway workshoppthreaded knob6mm nut355mmwashermspacerwasherkm6 x 40mm cuphead boltm8 x 50mm cuphead boltt54mmtemporaryalignment shim75mm x 10gcoach screwCutting list (all measurements in mm)70mm hinge6mm space belowmounting stripthe pegboardPosition the door assembly10Fixagainst the middlepartition and screw it intothe mounting strip from the middlepartition with four 40mm x 8gscrews. Add a magnetic cabinet latchand a door pull.900mm tofloortemporary90 x 45mmwall cleata cleatScrew a temporary11Position90 x 45mm to the wall,then locate and drill pilot holes inthe back of the assembly over thewall studs. Lift onto the wall cleat,position , then drive six coach screwsthrough the back into the studs.shim toheightaligncornersfront hanger stripthe benchShim the bench worktop12Hingeso that the barrels of thehinges line up with the bottom edgeof the front hanger strip. First drillpilot holes before securing thehinges to the hanger strip with40mm x 8g screws.Key Part Size (H x W) No.A Plywood sides 1215 x 275 x 19 2B Plywood top and bottom 1180 x 275 x 19 2C Pine hanger strip 1180 x 90 x 35 1D Plywood back 1085 x 1180 x 19 1E1 Plywood partition 1085 x 275 x 19 1E2 Plywood fixed shelves 581 x 250 x 19 2F Upper and lower face frames 1218 x 38 x 19 2G Outer face frames 220 x 38 x 19 2H Centre face frame 220 x 50 x 19 1J Plywood worktop 875 x 1180 x 19 1K Side aprons 875 x 70 x 19 2L Front and back aprons 1218 x 70 x 19 2M Legs 870 x 70 x 19 2N Worktop struts 875 x 70 x 19 2P Steel leg supports 460 x 19 x 3 4Q Pegboard door stiles 800 x 38 x 19 2R Pegboard door rails 460 x 38 x 19 2S Pegboard pieces 800 x 536 x 6 2T Mounting strip 806 x 38 x 38 1U1 Shelves 576 x 240 x 19 3U2 Shelves 576 x 240 x 19 4Visit www.handyman.net.au for a materials and tools list.94 SEPTEMBER 2007 Handyman Handyman SEPTEMBER 200795