In this detailed guide, Woodbrew demonstrates how to create a modern desk using minimal tools, making it an excellent project for anyone looking to enhance their workspace. The materials and tools needed for this project are straightforward, allowing for an enjoyable and productive woodworking experience.
Materials and Tools Needed
- Two sheets of plywood
- Wood dowels
- Triple thick polyurethane (for finish)
- Glue (Rockler’s glue recommended)
- Bar clamps
- Corner clamps
- Circular saw
- Edge guide (for circular saw)
- Sander
- Chisel and hammer (for adjustments)
- Forstner bit
Step 1: Cutting the Plywood Strips
To kick things off, the team uses an edge guide for the circular saw, which is a handy tool that comes with most circular saws. This guide helps in making long, straight cuts. They cut a total of 29 strips from the plywood that will make up the desk top.
Step 2: Glue Up the Plywood Strips
Next, it’s time for the glue-up. Using Rockler’s glue bottle with a glue roller and bar clamps, they join the plywood strips together. Initially, they face some challenges in getting everything flush, but with a bit of persuasion and by placing the assembly on sawhorses, they manage to achieve a good fit.
Step 3: Preparing the Cabinet Carcass
After the glue-up, they proceed to cut pieces needed for the cabinet carcass. A Rockler straight edge is used as a cutting guide, which is a cost-effective alternative to a track saw.
Step 4: Assembling the Cabinet
Once the pieces are cut, they assemble the outside of the cabinet using Rockler corner clamps. Before wrapping up for the night, they put together the two halves of the desk top, ensuring everything is ready for the next day.
Step 5: Making It Square and Smooth
They make adjustments to ensure everything is flush and flat. After using a circular saw to square off the edges, they sand the surfaces down for a smooth finish. They apply three or four coats of triple thick polyurethane for protection.
Step 6: Assembling the Drawers
Now, they cut all the necessary pieces to assemble three drawers. Using pin nails to hold everything together, they can then go back and secure with screws.
Step 7: Creating Drawer Pulls
In a creative twist, they use a hand saw and a coping saw to create the drawer pulls, eliminating the need for hardware.
Step 8: Installing Drawer Slides
They cut a groove in the cabinet for the drawer slides, which allows for a unique design element without the need for additional hardware.
Step 9: Overcoming Obstacles
During the build, they encounter several obstacles, including difficulties with their coping saw. They creatively adapt by using a chisel and hammer to create a breakaway point, ensuring a clean cut without tear out.
Step 10: Final Touches and Legs
The other side of the desk base is created using two-inch dowels for the legs. They drill inch grooves using a Forstner bit to securely fit the dowels.
Conclusion: Building Off-Grid
This project is especially notable as it was built entirely off-grid, using solar panels to power their tools. The total material cost for the desk was around $100, making it an affordable and sustainable woodworking project.
Woodbrew encourages everyone to dive into woodworking projects, reminding us that challenges are part of the process and that perseverance leads to rewarding results. For those interested, detailed plans for this desk can be found on their website.