This project was built and designed by Stan Sullivan. It focuses on maximizing tight, often-overlooked garage spaces using modular storage boxes made from scrap plywood and simple joinery techniques.
Stan’s design offers a practical and scalable way to add adjustable shelving and enclosed storage to narrow wall gaps. It’s a smart solution for woodworkers looking to reduce clutter, stay organized, and make better use of limited square footage.
Watch the full video and subscribe to Stan’s channel:
Making the Most of a Tight Space
Stan’s new garage is about 90 square feet smaller than his previous one. That might not sound like a lot on paper, but in a woodworking space, every square foot matters—especially when floor space is already limited by tools and workbenches.
To free up room, bulky items like lawn tools and bikes were moved to a backyard shed. That helped, but tools and supplies still piled up in corners and against the walls. Stan focused on one narrow area between an existing cabinet and the garage wall to test a better system—one that would finally put vertical space to work.
Learning from Past Mistakes
In a previous build, Stan created double-sided pegboard cabinets with the goal of keeping tools visible and easy to grab. Unfortunately, those cabinets turned into a lesson in what doesn’t work. Hooks regularly fell out, and over time, tools were no longer hung but stacked, defeating the purpose.
This experience led him to shift away from open hanging systems and toward closed cabinet storage with shelves. These new modular boxes are more secure, flexible, and better suited to how he actually uses his shop day to day.
Designing the Modular Storage Boxes
Instead of building fixed shelving units or investing in expensive hardware, Stan chose a modular approach that could be scaled, stacked, or rearranged over time. The new design consists of individual plywood boxes that fit into the available space and allow for simple customization.
Each box uses a basic construction method with butt joints, glue, and brad nails. For warped plywood pieces, clamps help keep everything square during assembly. This approach is ideal for shop furniture, where appearance takes a backseat to function.
Making Adjustable Shelves Without Shelf Pins
Rather than using metal shelf pins, Stan installed wooden shelf supports cut from scrap. These supports are screwed in at whatever height is needed and can be adjusted easily later. It’s a quick, low-cost method that offers the same flexibility as commercial systems without the added expense or tools.
This method also works well with inconsistent materials, especially if your plywood isn’t perfectly flat or square. The result is shelves that are sturdy and adaptable, even with limited tools or materials.
Fitting the Storage to the Space
Stan measured carefully to make sure the new cabinets would fit without interfering with nearby cabinet doors or trim. Each box was built to match the depth and height of the space, and once assembled, they slotted in like puzzle pieces.
By keeping everything modular, there’s no need to build one large cabinet. Each section can be removed, rearranged, or expanded as needs change.
Improving the Look with Paint
While shop storage usually doesn’t require a finish, Stan decided to give these cabinets a coat of paint. Since some of the plywood was low quality or mismatched, painting helped unify the appearance and added a layer of protection.
This small step gave the cabinets a cleaner look and made the space feel more intentional. It’s a good reminder that even functional shop projects benefit from basic finishing touches.
Why Modular Storage Works
Modular storage has several advantages over fixed systems:
- Custom Fit: Boxes can be built to exact dimensions for awkward or narrow areas.
- Expandability: Add more units over time without redesigning the entire wall.
- Affordability: Uses leftover materials and simple joinery to keep costs low.
- Flexibility: Can be rearranged or repurposed as your tool collection grows.
Stan’s approach shows that good shop storage isn’t about spending a lot—it’s about designing around your space and working habits.
Final Thoughts from the Build
This project is a strong example of solving real-world shop problems with practical design. Stan didn’t just build something that looked nice—he responded to past frustrations, thought through how he uses his tools, and made something better suited to his workflow.
He also made use of materials many woodworkers might throw away. Slightly warped plywood and leftover scraps became durable storage units with just a little extra effort and planning.
Get Stan’s plans here: https://www.simplyeasydiy.com/2014/11/diy-modular-shop-storage.html.