Hurry Up Project

My small workshop had to be re-organized  - again. Needed to make a low stand alone shelf where a couple of bench tools can be "parked". This is a hurry up project for an afternoon, so pocket hole joinery is the quickest way to put this project together. I've mentioned this before on an earlier blog that pocket hole joinery is the quickest way a novice woodworker can put together a project fairly quickly that will be robust and even aesthetically pleasing in a fairly short time. And a pocket hole jig is inexpensive.

I purchased 3 pieces of 2 X 4 X 96 inch (8 ft long) studs from the home center  for a total of about $10. 

First order of business is to cut them to manageable pieces with a hand saw (here, my favorite is a Japanese razor saw). It will be easier to handle them on the table saw.  Besides, it also takes care of slightly bent stock. In other words the cut off pieces will be straighter than he full length. Make sure to cut rough lengths that exceed the final dimensions of the pieces.

Note: For those without a table saw, a miter saw (cheaper but capable tool) will suffice by simply purchasing "dressed" lumber - those with flat sides on all four - that only needs to be cut off to lengths. Slightly costlier but saves the steps I did here, using the table saw.

These studs have rounded corners so first order of business is to rip one side trimming it flat

Trim the other side so now they're all 2-3/4 wide pieces. Cut the various lengths: 40 inch long for the two rails, 22 inch for the four posts and 10-1/2 for the four cross pieces. Measure and cut the center cross piece later.

Dry fitting

Drilling the pocket holes on the rails and cross pieces

Not completely shown is a full length bar clamp but typically a vise grip is all that's needed to hold the joinery while driving the screws. Since I have the bar clamps it is just quicker to have both ends taken care of.

A right angle chuck for the drill is indeed a huge helper when driving into tight spaces

Two equal vertical spacers  accurately positioned the lower cross pieces.

Note: The Krenov saw horses in the back ground were made using pocket hole joinery.

I started this project after lunch and finished by 5:00 p.m. with a coffee break in between. A hurry up project that is rigidly strong.

This will later have a plywood top.