“HPBooks PLYWOOD PLANBOOK American Plywood Association Complete plans for more than 40 indoor and outdoor projects you can build. Furniture, toys, planters, screens and more. How to select and work with plywood. Tips on cutting, fastening and finishing.PLYWOOD PLANBOOK American Plywood Association CONTENTS: Plywood Handbook How to Buy . Laying Out & Cutting Putting Plywood Together Assembling . Installing ..... Drawers .. Sliding Doors . Hanging Shelves Cabinet Backs . Choosing Hardware Plywood Paneling Interior Finishing . Exterior Finishing . Guide to Plywood Plans Plans . Index 157 Assistance: Patricia Bowlin; Art Director: Don Burton ‘Book Design & Assembly: Lioyd O'Dell; Typography: Cindy Coatsworth, Joanne Porter, Kris Spiter Notice: The information in this book is true and complete tothe best of our knowledge, Because of the individual ferences in tools and personal work habits, all recommendations are made without guarantees on the part ofthe futhor oF HPBooks The author tnd publisher dca al habit incored withthe use of hs information, Published by HPBooks; P.O. Box $367, Tucson, AZ 85703 602/888-2150 ISBN: 0-89586-034-1 Library of Congress Catalog Number: 80-80173 ® 1980 Fisher Publishing, Inc. Printed in USAFire Engine Bunkbed REAR WHEELS PANEL LAYOUT 2 RUWNING BonROS ‘aa I ALLONS FOR BEVELS 458 Panel of 1/2-nch PlywoodPANEL LAYOUT Fire Engine Bunkbed es BOTTOM BUNK 6195" ‘4x8 Panel of 1/72-nch Plywood S94 + 6 +—1894" 4x8 Panel of 1/2:inch Plywood)Fire Engine Bunkbed + 7i8ce FRONT 43% ae k |Wine Storage Rack MATERIALS LIST Quantity Description 1 2.x 4 plywood panel of 5/6 in. APA grademarked A~ A interior. Medium Density Overlay (MDO), oF textured siding panel 4-1/2 linear ft. 3/4 in. or 1 In. diam Sowel linear ft. 1/4 in. lameter dowel 4 Rubber glides As required Fine | sandal ‘smoothing cu plyweod and dowel ‘As required Wood filler or surfacing put- 'y to fil any small gaps in Plywood edges: ‘As required Paint or stain for fi hing CONSTRUCTION NOTES Lay out front on plywood using a gr to ensue proper shape. ‘Gut out front and use it to layout back. Gut “out ‘back’ Clamp front and ‘back together for inal smoothing. Fill and sand edges, fut 3/4-Inch dowels into five 10-1/2ineh lengths, Dril dowels as shown on plans, Sit holes for botties on trant and back shown in plans. Drill holes for dowels. 3/4- inch dowels should fit tightly in holes, Su ene owas no twenty 1-1/2 inch pins. Fi a/e-inch dowels into front and back ‘ang pin with 1/4-incn dowel pins, Paint or stain as desired Attach rubber glides to bottom. DOWELS iT Ya 1a power. | | ye" - (MAKEZO) ae | 3/4" DIA. DOWEL (MAKE 5) ' iW : J ‘ Qu er arFold Away Vise Table & Sawhorse MATERIALS LIST Quantity 1 2 4 pieces 2 pieces 4 2 2 20 (approx) 8 (approx) 8 2 z ‘As required ‘As required ‘As requires As required Description domarie AB Gr kb Ineo AB or BC Erte, or Mecium Deneity Overay (MOG) Strap hinges, 1-1/2 in. with screws Angle tron, 1-1/2 9.x 2 in Threaded rod 2/8 in, diameter x 18 in. ona Nuts, to ft 2/8 in, diameter threaded rod Bolts, 1/4 in. dlameter x n.1ong Lock nuts, 2/8 in. elameter x 1/2 in. deep 1-1/4, #8 fathead wood screws 2in, #8 flathead wood screws 1-1/4n, 48 rounchead wood screws Carriage bolts, 1/4 in. diameter x 2 in. ong, with wing mute Compression pins, 1/8 in. diameter x 1/2 in. long Wood dough for fling any small voids in plywood edges. Fine sandpaper for smoothing edges and cured ‘wood dough White glue for glue-screw assembly Finishing mat CONSTRUCTION NOTES Lay out parts on plywood. Center saw cuts on layout lines to equalize saw ker! width on all parts. ‘Cutoff the able top section and cut tin hat, Set these two sec tions aside, Cut out sther parts, ‘Clamp sawhorse legs together and cut slots simultaneously, outer using’ rowteror making paral cute along sles and Femoving slot material with hammer “and chisel, Repeat for Sawhorse ands. Lightly sand cut edges smooth. Slige sawhorse ends into leg slots to check ft. Adjust it necess- fap with hinges. ions together using glue accord ufacturer's instructions. Clamp Until ory Cut the Iami- fo two 73-inch wide sections. “Assombie runner channels on side and bottom plates and fasten to the stationary section of the table top, as shown in detall. Be will nt bind. Use glue and 2- 3 screws where channels fasten to top. Use 1-1/4. inch #8 flathead screws on other hal. Alach spacer plato using Glug and 1-1/4-Inon #8 screws Pace runner slides in runner channels and lay movable table section In position on top of slides. Mark positon of slides on Underside of movable table section ang then, using 1-1/4-Inch #8. flathead screws, glue-serew slides fo movable table section as shown n exoied view. This assures that ages wilrun rue wih Hinge legs to stationary table top assembly as shown in bottom and front views. Note thal the spacer plate on one side allows legs fet et Alo rata ringes nat asin cross braces to loge. ment in end and front views. Where cross braces over tap, ils o/16-inen hole through cross braces, insert carriage Dalis and wing nuts. These remove for storing table, ‘/16-Ihch hole through a lock nut and tap R with 1/4 inch thread: tf you do not have the proper equipment'a. machine shop Can do this and the ailing below for you, Place nut to act ae han. Sle/red connector on one.end on the threaded rod and insert one ‘te inch bots. Bond end a bolt fo form a handle, Repeat or Dril two 3/16-inch holes in one flange of each angle iron to ‘accommodate 1-1/4-Inch #8 rounghead mounting screws, Center {25/6-inch hole in remaining flanges of angie irons to be installed 3nd tap fo fil the threaded rod. Center 2 femaining flanges of angle irons to be instalied ‘section as shown in the detal Using 1-1/4-inch roundhead screws, fasten angio irons beneath table sections as shown in the bottom view anc detail Set iron {lush against inside edges of runner channels. 7/16-inch and 8/ é:inch holes grilled in flanges should align, front tor inoall threaded 2/8-inch diameter rods an hardward a8 shown {in detail. Ori 1/6-inch holes through retaining nuts and rod. Insert compressing pins fo lock in plac ‘Woodworkers may want f0 dll a configuration of §/8-Inch holes In the vige-table top and Use owels to hold « wide variety of Shapes and sizes of woodwork, lemove movable section and carriage bolts betore finishing Fil any’ small voids in plywood cut edges with wood Gough. Let dry {and sand smooth. I esied, finish with primer and paint according {fo manufacturer's directions. De ‘not paint runner channels oF slides: Wax runner slides before reassembling ine vise table.Foldaway Vise Table & Sawhorse PANEL LAYOUT ea poe ey Vise TABLE TOP 12x36" Aas eae 2 RUNNER SLIDES. 2x 2386" 4x8 Panel of 9/4-inch Plywood a SAWHORSE why aM gh pe 4% | = Hide fa $ sxe L U | J It i fet see” 85Foldaway Vise Table & Sawhorse VISE TABLEWine & Glass Rack 88 MATERIALS LIST Quantity Description 1 4 ft x 8 fl plywood panel of 1/2 in. APA gra Gemarked A-B or AD Interior A.B or A-C Exterior, ‘or Medium Density Overlay (MDO) 4 1X28, 25 in, long, for face trim, Miter at corners. 2 optional) 12in.x 12 in. mirror tes 20". (approx) 1/2 in. wide wood veneer trim for bottie-rack edges: v2 4d finishing nails for glue-nail assembly (approx) ‘As required White glue, approximately 80. boltl, for glue-nall assembly ‘As required Fine sandpaper for plywood edges [As required Wood dough for plywood edges ‘As required Finishing materials CONSTRUCTION NOTES rs,on plywood. ‘parts. Center ci “ogether in stacks: four 6 x 16 Inch shelves with three slots each, wo 6x 16 inch shelves with one slol each, and and so forth. Mark exact centerline of slots on panel edges. ‘Unclamp and mark halt the slot width, 1/4 inch, on Bach side of tho matched centerline markings. Oraw slots accurately on each pleco and cut out, using saw and chisel ora router. To cut gl anger slots, draw each one on the panel pieces. Rounded ends ‘may be shapes with a jigsaw or router or with 8 8/6-Inch ori 1nd oF hile to final configuration, 1W cut on layout lines to equalize saw 2 le. ADpY glue Io slots according to manufacturer's drec- semble, Secure onde with nails, Set nails, fil holes hand sand smooth Back ploces side by side and draw lines across ck locations. Using glue and nail, Join back, sides, bottom and top as shown in exploded view. ‘Giue and nal glass-nanger rack ang shell in place, and install ior tiles, Set sil exterior nal he a InFinon Bote rack and cabine! nai as desired. et bot rack in place. Apply ge to corer tings, ihetall 1x2 face tim, using glue and nails Finiah exterior a8 dosired. You may apply wood ve rack e3ges; oF fill any edge voids with wood dough, when dry and varnish or paint