Dewalt Organizer Storage Cabinet Plans
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1 Dewalt Organizer Storage Cabinet Plans Version 1.0 How to build a system to perfectly organize you Dewalt storage organizers. With easy to follow step-by-step instructions, you will be able to cut, assemble, and finish your very own storage organization system, Plan set preview: 29 pages 50 pictures Material list, cut list, and assembly instructions Material, hardware, and other supply sourcing
2 Bill Of Materials Material 4 x 8 x 3/4 sheet good (plywood, MDF, etc.) Quantity One full sheet Half sheet Hardwood (oak) Two 6 x 96 3/4 boards 2 Screws (case assembly) 55 3/4 Screws (caster installation) 16 (Four each) 2 1/8 or 2 1/4 84 (Three each) Wood glue Swiveling Casters with locking mechanism One bottle Four Workshop Addict Copyright 8/2/2016 Page 2
3 Cut List Part Quantity Dimensions Back Sheet good Sides Sheet good Vertical Divider Sheet good Top/Bottom Sheet good Wooden Drawer Guides Hardwood long x 29.5 wide x.75 thick long x 15 wide x.75 thick long x wide x.75 thick 29.5 long x 15 wide x.75 thick 14 long x 1.25 wide x.75 thick Workshop Addict Copyright 8/2/2016 Page 3
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15 Use this layout if you want all the parts to be plywood. Specifically, the runners/guides. Workshop Addict Copyright 8/2/2016 Page 15
16 Step 1: Cut all your parts to size Consult the cut list and diagrams at the end of the plan for the dimensions. Using whatever tools/resources you may have, cut your parts to size. I used my table saw, track saw, and miter saw to easily break If you are using a track saw, place foam on the concrete/ floor to protect your blade! Workshop Addict Copyright 8/2/2016 Page 16
17 Step 2: Marking the screw locations This carcass will be constructed with simple butt joints and several screws per joint. together. The plans have all the holes marked for every joint. Step 3: Assemble! The entire cabinet is a simple box with a vertical divider in the middle. Start by attaching the top and bottom to the sides. Then mark the location of the middle divider and secure with screws. Don t put on the back just yet. It will make installing the runners/guides much easier. Tip: Use clamps and corner jigs to keep everything in position when drilling and driving the screws. Workshop Addict Copyright 8/2/2016 Page 17
18 Step 4: Apply glue, pre-drill, and drive the screws I am using Fastcap s Powerhead screw system. They are an extra large washer head type screw. They are not necessary but provide a clean look and extremely strong joint as the washer will grab the side extremely well. Regular wood screws will certainly do the job as well. Pre- drill with a drill bit and a counter sink or complete in two separate steps. The Powerhead system from Fastcap drills a shallow pilot hole and also a flat recess for the washer head of the screw to fit perfectly in. I then use a regular drill bit to extend the pilot hole. With a square drive bit, I drive the washer head screw. Workshop Addict Copyright 8/2/2016 Page 18
19 Step 5: Mill the hardwood runners/guides Mill your hardwood runners/guides to a thickness of 3/4 and a width of 1 1/2. Once they are milled to the correct dimensions, cut them to 14 in length. This leaves a 1 gap from the back to allow for some fine tuning when installing the back. Ease those edges! It is more convenient to ease the edges with a block plane or some sand paper when the runners/guides are not yet cut to length. Workshop Addict Copyright 8/2/2016 Page 19
20 Step 6:Cut the angled relieve on the runner/guides The design of the unit allows for approximately 1/4 above each Dewalt storage unit, but it can be difficult to insert if the runners/ guides have a sharp front corner. We can solve this by cutting a small 45 degree chamfer on the front of the runner. This will prevent the storage unit from getting caught on the sharp corner. Workshop Addict Copyright 8/2/2016 Page 20
21 Step 7: Drill and countersink mounting holes The runners/guides are secures with three (3) screws. I used pan head screws that needed a little countersink to get the correct depth. The screw dimensions in the plan don t require the precise countersink. Drill the countersink, extend the pilot hole, and, if needed, apply a small countersink to the back side if there was any chip out. This chip out could prevent the runners/guides from sitting flush when being installed. Step 8: Install the runners/ guides Place the runner/guide on the a 4 3/4 spacer. Then apply one clamp on each end to keep it in position while you drive the three (3) screws. Make sure the angled cut is in the front and facing up. Workshop Addict Copyright 8/2/2016 Page 21
22 Step 9: Install the back With the runners/guides in place, the back can now be installed. Simply put it in place, drill your pilot holes and countersinks, and drive the screws. The back is held in with a bunch of screws as it is Tip: Use clamps to apply a little pressure to the sides and then use your hand to push the back in or out to get it flush. Then apply more clamping force and then drill your pilot holes and countersinks and then drive the screws home! Workshop Addict Copyright 8/2/2016 Page 22
23 Step 10: Install the casters Casters are not necessary but I like the thought of being able to wheel all my hardware (well at least most of it) to the assembly table or my work area. Installing the casters is very simple, place them on the bottom giving them a 1/8 from the edge and drive with a screw. It is important to use a pan head screw or a regular screw with a washer as typical casters have a large mounting hole that is meant for a large lag screw. Workshop Addict Copyright 8/2/2016 Page 23
24 Step 11: Load the storage organizers and enjoy! With the project complete, it is now time to load the organizers with the screws, nuts, bolts, and all the other hardware and nick knacks you may have and put them in the cabinet. Workshop Addict Copyright 8/2/2016 Page 24
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