Loading plan…
Loading plan…
Step-by-step build — 9 steps. Also available as a print sheet.
Rip the plywood sheet into 15-3/4"-wide strips for the sides, shelves, and top. Before any assembly, go through the whole plan and mark and drill every pocket hole — several become unreachable once the carcass is joined. On each side, on the outside edges with no pocket holes, attach the side trim to the top and bottom with 1-1/4" finish nails and glue, flush to the outside edges. You need two identical sides.
With top edges flush, attach the legs to both sides using 1-1/4" pocket hole screws and glue.
Measure and mark the placement of the front and back trim boards, then attach with 2-1/2" pocket hole screws and glue.
Drill 3/4" pocket holes on all sides of the fixed shelves. Attach with the side trim, flush at the tops, using 1-1/4" pocket hole screws and glue.
Build the top with 3/4" pocket holes and 1-1/4" pocket hole screws, then screw it on from the underside with 2" screws and glue.
Cut the plywood back to fit and attach with glue and 1-1/4" finish nails, making sure to catch every fixed shelf. Cut any cord-pass holes now, before the back is closed in.
Drill 3/4" pocket holes on each end of the shorter door pieces and build the door frame with glue and 1-1/4" pocket hole screws.
Predrill holes in the acrylic glass and attach it to the back side of the door frame — this significantly stiffens the door. Mark the hinge locations first and notch the acrylic (or cut it slightly short on the hinge side) so the hinges have a clean, flat mounting spot.
Mount the Euro-style concealed hinges, which need generous clearance — test-fit before committing. Leave a 1/8" gap on every side of the door so it swings freely, add the knob, sand every surface, and finish.