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Cut and Dimension Wood Components

From Under Stair Storage · Step 4 of 7 · Video by John Heisz - I Build It

Showing 0:40–2:20 of the source video. Watch the full video with every moment.

What happens in this clip

Using a table saw with a crosscut sled, precisely cut the 1/4 inch plywood into the required sizes for the drawer bottoms, front panels, back panels, and dividers. The video uses floor underlay plywood, which often has markings (like 'X's) for installation; these can be ignored or sanded off later. For the very thin divider pieces, use a push stick or featherboard for safety and accuracy. Then, retrieve solid wood boards from storage to be used for the drawer sides. Using a table saw, rip these solid wood boards into thin strips. After ripping, use a surface planer (like a DeWalt planer) to smooth and dimension these strips to the exact thickness required for the drawer sides. Once the strips are planed, trim them to the correct width on the table saw. Finally, using a miter saw, cut all the thin strips (drawer sides) to their final length. For efficiency, stack multiple strips and cut them simultaneously.

Step 4 of 7: Cut Components

Using a circular saw, table saw, or jigsaw, carefully cut all the pieces for the drawer boxes, frames, and any other structural elements. Ensure all cuts are straight and accurate to ensure a good fit during assembly. If cutting large panels, consider having them cut at the lumberyard to save time and ensure precision.

Open this step in the guide

Every video in Under Stair Storage

  1. Step 1: Measure Under-Stair Space

  2. Step 2: Design Storage Units

  3. Step 3: Select Materials

  4. Step 4: Cut Components

  5. Step 5: Assemble Storage Units

  6. Step 6: Install Storage Units

  7. Step 7: Attach Handles and Finish

Questions about Under Stair Storage

The project summary lists an estimated time of 4 minutes, but it seems more complex. How long should I realistically expect this project to take?

The 4-minute estimate is likely a typo. Given the design, cutting of plywood, assembly of units, and installation, this intermediate project typically requires several hours to a full weekend, depending on your experience and the complexity of your design. Plan for at least 8-16 hours of work spread across multiple sessions.

What are the most important safety precautions I should take when building under-stair storage units?

Always wear safety glasses when operating cutting tools to protect your eyes from flying debris. Use gloves to prevent splinters, and ensure your work area is well-ventilated if using adhesives or finishes. When installing, securely anchor the units to the studs or solid framing to prevent tipping.

What kind of wood is best for these storage units, and how can I estimate material costs?

For durability and a good finish, 3/4 inch birch plywood, as listed in the materials, is an excellent choice. You'll need to precisely measure your under-stair cavity to calculate the exact amount of plywood, drawer slides, and caster wheels required. Expect material costs to vary, but budget a few hundred dollars depending on hardware quality and wood choice.

How do I accurately measure and design the storage units to fit my unique under-stair space, considering the slope?

Start by measuring the height, width, and depth of your stair cavity at multiple points, as walls are rarely perfectly square. Account for the stair's slope by creating a template from cardboard before cutting your final materials, ensuring your units will slide in and out smoothly without catching.

What are common mistakes DIYers make with under-stair storage, and how can I troubleshoot them?

A frequent mistake is inaccurate measurements, leading to units that don't fit or operate smoothly. Double-check all measurements before cutting and create a detailed cutting plan. If drawers stick, check if slides are level and plumb, and ensure there's enough clearance around the units.

Are there alternative materials or drawer mechanisms I can use if plywood and standard slides aren't ideal for my project?

Yes, for a different look or budget, you could consider solid pine boards for a rustic feel or MDF for painting, though MDF is less durable. Instead of traditional drawer slides, you could build simpler pull-out bins directly on caster wheels, or opt for fixed shelving if full drawer access isn't a priority.

Why are items like 'Designer Stencils' and 'Primed Baseboard Moulding' listed, and how are they typically used in this project?

These items are for aesthetic enhancements. Designer Stencils could be used to add decorative patterns to the drawer faces or the inside of the units. The Primed Baseboard Moulding would likely be used to trim out the exterior opening of the under-stair cavity, giving the installed units a more finished, built-in appearance.

Under Stair Storage

This project involves designing and building custom drawers or pull-out carts to maximize storage space within the often-underutilized area beneath a staircase. The process includes measuring the space, designing the storage units, selecting appropriate materials, cutting and assembling the components, and installing them into the stair cavity.

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Cut and Dimension Wood Components — Under Stair Storage | Oak Valley Designs

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