In the first installment, I made the simple statement “I bought some lumber.” That is true, but, of course, it’s never that simple. I ordered everything online from Home Depot but never saw any place to say that I want it delivered. I have no vehicle in which I can carry 4×8 sheets of OSB. In the end, I was asked for a shipping address, so I supplied it. It turns out that the two smallest items on my order (the only things I could fit in the Lotus) would be shipped to me, but not the rest.
I called the store to say that I need my order delivered. I got a bit of a run-around. Eventually, they said that when I got a text message saying my order was ready for pick-up, I should call and tell them I want it delivered instead. I got an email, not a text message. And it said my order was only partially ready. I called them anyway.
After some more run-around, the solution was that a clerk there in the store would delete my order and re-enter it, specifying that it’s for delivery. I’d have guessed it would be much easier for them to simply add a line-item for the delivery charge and be done with it, but what makes me think anything should be simple?
They told me to expect delivery on Friday (the 13th). I asked if they could give me an approximate time. “Give us a call on Friday morning and we’ll let you know.” So I called promptly at their opening time. I was told that it might arrive sometime around 12:30. At about nine I see a forklift dropping my lumber in my driveway. I ran out and talked to the guy, hoping there was a way to get it into the back yard. No deal on that. And when I told him the store said he’d be here at 12:30 he just laughed. “They have no idea when I’m going to deliver anything.” Why should I expect anything different?
I managed to get it all moved to the back yard by myself. It was a bit of a struggle with the big sheets of OSB, but I managed.
Here is my lumber, mostly out of the weather on the back deck, along with the carcass of the drawer section of the old workbench. I’ve covered the lumber with a tarp for when it snows, but the tarp is slightly too small and has a few holes in it. So it goes. I’m sure everything will survive.
The critical part of these new cabinets, I think, is the base. The weak base was certainly the Achilles heel of the old cabinets. The challenge here is dealing with the uneven floor. I figured out how to scribe the shape onto the lumber so I could make a reasonable stab at cutting them. I guess I finally get some real-world benefit from watching all those This Old House episodes!
The next issue I had to deal with was how to cut up my OSB. The biggest challenge is to rip two 4×8 sheets into four 2×8 sheets for the walls. Then, for the shelves, I’d need a bunch of sheets two feet by not quite four feet. I’m lucky to cut a 2×4 straight. I decided the way to go was to get the Kreg rip cut guide. Run it along the milled edge and even I can get a nice, straight cut.
I don’t have any sawhorses, and even if I did, I’m not sure I’m capable of doing an eight-foot long rip on them, so I figured the way to go was to get a big sheet of solid foam insulation and do all the cuts on my deck. I can kneel on it, I can walk on it, and it’s two inches thick so there’s no way I’ll accidentally cut all the way through it. This combination worked like a charm. You’ll spot that sheet of foam lurking in many of my pictures.
Rather than putting the cabinets together and then painting them, I figured it would be better to cut all the wood to the proper size and paint it before putting it together. This assumes some skills that I may not actually possess. The good thing is, I’m building garage cabinets instead of kitchen cabinets. Nobody wants me to build kitchen cabinets! If I’m a bit off on my cuts, my mistakes should be well hidden by all the junk I’ll be storing.
The color coat went on easier than the primer, for two reasons. First, I learned from my mistakes on the primer coat. The big pieces of OSB were no problem, but the sticks of 2×2 demanded a proper procedure. By the time I was done with priming those, I came up with what I think is the most efficient methodology. Second, the color coat dried a lot faster than the primer.
Here I am holding up the first assembled side wall. It’s pretty much square, plumb, and level. And I’m reasonably certain I have the hinges in the correct places. The challenge was in getting it secured. It’s not lined up with a stud, so I can’t just screw it to the wall. I need to mount the cleats for the top, bottom, and shelves first, then fasten the wall to the cleats. With Michael’s help, I managed to get the left side cabinet walls put up. And, because everything is easier the second time, I was able to get the right side done on my own when Michael was at work.
Here we are with some shelves in, to make sure everything is still square. In order to get the shelves in, I needed to take off one of the hinge mounts on each cabinet. And, yes, they have a different number of shelves on purpose. This mimics how I had the prior ones set up. Those shelves were adjustable, but I had them set up like this and never moved them in twelve years.
The clever observer will note that the doors are too wide. And they’re not gray, like everything else. It took me a while, but I figured out how to adjust the hinges to get the doors to hang straight. They’re too wide because the cabinets are about an inch narrower than the old ones, and the walls are thicker by an inch and a half. So the hinges are about four inches closer together than they were before. The plan is to rip the doors to size, then sand the faux wood grain laminate finish enough to take paint.
I still have quite a bit of work left to do. The drawers will fit between the left cabinet and the wall and I’ll put a small cabinet above them. And above the pegboard in the center will be a shallower cabinet, sixteen inches rather than twenty-four. Finally, I’ll build a workbench in the center. It’ll be a bit deeper than the one I’m replacing, and stout enough to handle a nice vice.
Before I began, I guessed that I would be able to complete this project in 32 hours, not counting the demolition. Up to the point in that last photograph, I’ve logged 25 hours and I’m maybe halfway done. It should be no surprise that I’m not much better at estimating carpentry projects than software projects.