Concrete Countertops – The Reveal

Thanks guys for sticking with us through five yes FIVE posts on concrete countertops. The thing is, this project was BIG. Even with five posts I have probably bored you all to death with my insistence on telling you exactly how we did everything. The thing is, I want you guys to make your own counters too! You CAN do it! Real concrete, solid surface, with professional looking results. So thanks for sticking with me, cause I think it was totally worth it. Wanna see what all our hard work actually looks like?

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The counters were done in four pieces, including the single piece waterfall, which is by far my favorite piece! The color we used is “coal” but the color of the concrete can look very different at different times of the day. From a medium gray when the light is hitting it to a deep charcoal in the shadows. The color has so much texture and movement. I just love it! We paired the white cabinets with a pop of bright teal, and black and white accents.

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For the back of the peninsula we opted to add a pop of wood. The kitchen already had a lot of white, so adding wood really ties it into the dining room with its wood table & bench. It also matches the floating shelves on the coffee bar.

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The waterfall is just sexy! I love how seamless it is. I would never have dreamed that we could do it in one piece. It is  simply a work of art.

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Speaking of the color varying. Here is one of my favorite spots with a lot of texture. This was produced by adding a slightly lighter color slurry for the middle slurry coat. I heart.

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The front of the peninsula has cupboards, and when you open them you can see more of the exposed waterfall.

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Sorry, had to throw one of Odin in. I can’t have my camera out and not take a photo (or ten) of him.

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Do you remember when we hid a 2013 Loonie? Here’s the Queen peeking out from under the coffee bar counter.

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Now for a few of the other kitchen details. El Granto picked me up a couple vintage Bell jars one day at The Junction Flea. I love this one which holds my wooden spoons beside the stove. We also use a small ceramic tray to keep oil and vinegar off the counter (it would stain the tops).

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I am still very happy with the wood shelves we added to the coffee bar. Now with the wood clad peninsula, it really pulls the coffee bar into the kitchen.

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The inside counter was one piece I worried about a lot, but in the end its imperfectly perfect.

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Okay, one more pic of the waterfall! We slightly rounded the counter edges. Littles and dogs wont poke their eyes out, and it makes me swear less when I bump into the counters.

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So what do you think?! We’re super happy with them. They turned out better than we ever could have imagined!

I will be back later in the week with a few more kitchen items. Such as the source list, a few more project how to’s, as well as how we installed and sealed the counters. But for now, I am going to go and makeout with my counters. Wha? Uh. I mean stare at them lovingly, and maybe touch them a little. So smooth… and sexy…

This project is part of Project Concrete Countertops. Make sure you check out the rest of the series starting with Concrete Countertops – The Mix, The Templates, The Forms, The Pour, Fill & Sand,The Reveal and Finishing Touches.

Buddy Rhodes

*We were gifted some (awesome) Buddy Rhodes Concrete Products, but all opinions are our own!

P.S. We’re participating with Creating with the Stars this year! Make sure to check out East Coast Creative and vote for us!

Farmhouse Table Reveal + Plans

Aaaaand were done! Daniel and Adelle moved into their new place and took their newly finished modern farmhouse table and benches with them. Mind you as much as we will enjoy our garage space back, we will miss working with Daniel and Adelle on this project! It’s different working with friends than a spouse, it’s laid back and there (usually) isn’t any swearing involved. Throw in a piña colada or two, and it’s a party with work involved.

If you missed the beginning of the project, check out part one, two, three, and four.)

So without further adieu, here is the table!

Farmhouse Table

Farmhouse Table

Farmhouse Bench

It fits perfectly in their narrow condo, and the benches hide away completely when not in use, making this table able to function as stand in kitchen prep surface.

Farmhous Table

The deep stain color works great with their white walls and light floors.

The table also does a mean job of holding a glass of wine or two (we had to test the table out…come on!)

wineinsta

SPECS & PLANS:
The table is loosely based on the Ana White farmhouse table plans. (We changed size, removed the breadboard ends, and used dowels instead of screws for the table legs. ) For in depth instructions on how to assemble the table check out her plans here.

Farmhouse Table

tableplan

 

Lumber Buy List:

5 – 2×4 @ 8′
3 – 2×10 @ 8′ (we used kiln dried pine from Downtown Lumber for the table top, it was worth the extra expense! If you cant find kiln dried pine, purchase spruce 2×12’s from your local hardware store, and rip down to 9 1/2″ wide removing the beveled edges while you’re at it (they will be huge crumb catchers if you leave them)
1 – 4×4 @ 10′ (if you cant find 4×4’s in untreated spruce or pine, use cedar)

Cut list:

4 – 4×4 @ 29″ (legs)
2 – 2×4 @ 78″ (long aprons)
2 – 2×4 @ 17 1/4″ (short aprons)
1 – 2×4 @ 85″ (stretcher)
2 – 2×4 @ 24 1/4″ (stretcher supports)
3 – 2×10 @ 96″ (table top pieces)

Instructions:

Cut all lumber to length.

With Kreg Jig set to 1 1/2″ material, drill one pocket hole every 8″ or so on one side of two of the table top pieces (the outside tabletop boards). Then attach the outside table top pieces to the center table top board with wood glue and 2 1/2″ pocket hole screws. (see our post on building the table top here.)

Drill Kreg Pocket holes on top and sides of all apron pieces. Make 2 holes on the ends, and a hole about every 8″ on the tops.

Notch out legs for the stretcher supports. Make notches 3 1/2″ high by 1 1/2″ deep positioned 6″ up from the bottom of the leg, and 19 1/2″ down from the top of the leg.

Notch out stretcher supports. Make one notch in the center of each stretcher support. Make notch 3 1/2″ wide by 1 1/2″ deep.

Assemble legs by attaching short aprons to legs (inset by 3/4″) then set stretcher support into leg notches, and attach with screws or dowels (see how we did the dowels here).

Attach long aprons to legs, with pocket screws.

Flip tabletop upside down, center legs upside down on the table bottom, and attach legs to table top with pocket hole screws.

Attach stretcher to stretcher supports with screws or dowel.

Sand, stain & finish as desired.

Farmhouse Bench

(for TWO benches, halve the amounts if you’re only making one)

benchplan

 

Lumber Buy List:

7 – 2×4 @ 8′
2 – 2×12 @ 8′ (7′ if possible)

Cut List:

8 – 2×4 @ 16 3/4″ (legs)
2 – 2×4* @ 61″ (aprons) *= we ripped a 2×4 down to 2″ wide. You can also buy 2×3’s instead of 2×4’s
2 – 2×4* @ 6″ (short aprons) **= we ripped a 2×4 down to 2″ wide. You can also buy 2×3’s instead of 2×4’s
2 – 2×4 @ 61″ (stretchers)
4 – 2×4 @ 6″ (stretcher supports)
2 – 2×12 @ 77″ (bench tops)

Instructions:

Cut all lumber to size.

Drill pocket holes on apron pieces (Kreg set for 1 1/2″ thick material). Two holes on each end, and about every 8″ on the top. Drill two pocket holes on top of small aprons. Drill two pocket holes on each end of stretcher supports. Drill two pocket holes on each end of stretchers.

Attach stretcher supports to legs 3 1/2″ up from the bottom with 2 1/2″ pocket hole screws. Attach long aprons to legs with pocket hole screws.

Flip bench top upside down, and attach legs (also upside down) to bench using the apron pocket holes and pocket screws. Attach side aprons to bench top. Attach stretcher to stretcher supports.

Repeat for second bench.

Sand, stain and finish as desired.

 

SOURCE LIST: (one table + two benches)

Materials:

Lumber (see above)
Minwax oil based stain in Jacobean
Minwax wood conditioner
Polyurethane – Minwax Oil Modified in Satin
200 2 1/2″ Kreg pocket hole screws (Lee Valley)
Wood Glue
Foam brushes (Dollarama)
Rags
Sandpaper (150, 220 and 320)
Kreg Screws – Lee Valley & Home Depot

Tools Used:
Miter saw
Table saw *not necessary, you can get material ripped to size at the lumber yard
Circular saw
Square
Kreg jig
Drill
Palm & orbital sanders
Measuring Tape

Difficulty Level (on a scale of 1-5):

three out of five

Total Cost: $400 (Lumber $320, Screws $20, Finishing materials $60)
Time frame: Two weekends (one to build, one to finish)

Printmakers Media Cabinet – The Reveal

Its been six weekends of hard work, but we finally reached the final stretch of the printmakers media cabinet project.

This is where we left off. The cabinet was built and sanded and ready for finishing. If you missed it, check out part one, two, three, four, and five of the project.)

Cabinet built
Cabinet built and ready for stain & hardware

Next up we took all the drawers outside, and set up a staining station, and gave everything a coat of wood conditioner.

Wood Conditioner
The drawers & doors ready for wood conditioner
DIY Tip: Put your cabinet on scrap wood to make it easier to stain the bottoms of the legs
DIY Tip: Put your cabinet on scrap wood to make it easier to stain the bottoms of the legs

After letting the wood conditioner sit for half an hour, we set out to staining. We had done many a test on stain, and came across a cool technique we wanted to try on the cabinet. It involved wetting the wood, then putting on oil based stain on top of the water, then quickly wiping away. It left an almost zebra like effect. We knew it was going to be a risk, but decided to give it a try none the less. It involved several hours staining, many a swear word, lots of teamwork, and a whole lot of second guessing.

Cabinet stained
Cabinet stained

We took two days to stain everything, the first day we did the cabinet and all the drawer & door fronts. The next day we stained the interior of the cabinet and the drawer boxes. For the interior, we didn’t bother doing our stain technique, and instead just used the stain traditionally.

After the stain dried, we applied several coats of polyurethane, sanding with a 320 grit sandpaper in between coats. We put a total of 5 coats on the top of the cabinet, and three everywhere else.

We use Oil-Modified Polyurethane with a foam brush
We use Oil-Modified Polyurethane with a foam brush
Drawers & doors mid-polyurthaning
Drawers & Doors mid-poly

Once the poly had dried, we set to installing hardware. The screws that came with our cup pulls were too short for the double thick drawers, and too long for the single thickness doors. So we headed to the hardware store and picked up longer screws for the drawers, and El Granto cut down the screws with the dremel for the doors.

Ready for Hinges
Pulls attached to door fronts, and ready for hinge installation

After the handles were installed, we set to installing the hinges, stays and clasps for the doors.

Installing hinges on the doors
Installing hinges on the doors

This involved a whole load of finikity work, lots of tiny screws, and stubby little screw drivers to fit into the cabinet.

Attaching hinges to the cabinet
Attaching hinges to the cabinet
Attaching claps to keep the doors closed
Attaching claps to keep the doors closed

Next up, we needed to add the lid stays to make sure the doors dont open too far. We wanted them to stop at 90 degrees.

Installing lid stays
Installing lid stays

We used a square to hold the door at 90 degrees and attached the stays with small screws.

Now we could set to putting all our electronics into the cabinet. To keep things neat, we installed power bars to underneith the back of the shelves. This keeps the cords off the ground, and makes it so that the cabinet can sit flush with the wall.

The view of underneath the shelf in the cabinet showing the power bar.
The view of underneath the shelf in the cabinet showing the power bar.

We routed all the cables and electronics as best we could through the cabinet, and its so much more organized than our old media center!

The electronics all tucked into the cabinet
The electronics all tucked into the cabinet

Enough with the technical stuff, are you ready to see what it looks like all finished?

DRUMROLL PLEASE

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Drawer

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Now a little comparison between our cabinet and our inspiration: the Restoration Hardware Printmakers Media Cabinet. (ours on top, the RH cabinet below)

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What do you think?!

SOURCE LIST:

Plans:
DIY Plans for an RH Inspired Printmakers Media Console – Design Confidential *(a BIG Thanks to Rayan @ Design Confidential! Her plans are awesome!)

Materials:

Hardware: ($130)
15 cup pulls – Lee Valley
6 inset hinges – Lee Valley
6 sets drawer slides – Lee Valley
3 lid stays – Lee Valley
3 cabinet clips – Lee Valley
8 1 1/2″ felt furniture pads – Dollarama

Lumber: ($100)
8 – 2x2x8 – Downtown Lumber
2 – 1x6x8 – Downtown Lumber
5 – 1x10x6 pine shelves – Home Depot
3 – 1x2x8 Downtown Lumber
6 – 1x4x8 – Downtown Lumber

Finishing/Misc: ($50)
Wood conditioner (already owned)
Stain – Varathane “Kona” – Home Depot
Polyurethane – Minwax Oil Modified in Satin
Minwax Stainable wood filler – Home Depot
Kreg Screws – Lee Valley & Home Depot
Foam brushes – Dollarama
Shop rags
Sand paper

Tools Used:
Kreg Jig
Drill
Mitre saw
Table saw
Palm sander
Square
Level
Wood clamps
Corner clamps
Short Kreg drill bit
Stubby screw drivers

Stats:

Trips to lumber yard -4
Trips to hardware stores -10+
Coats of polyurethane – 5 on the top, 3 everywhere else
Stain samples made before deciding on one – 11
Time involved – 6 weekends, 70-80 hours total
Number of electronics in the cabinet – 11
Number of screw-ups – 3
Number of arguments – 2
Total pieces of wood – 119
Screws – about 300
Injuries – 0!
Swear words – more than I’m proud of

Difficulty Level (on a scale of 1-5):

five out of five

Total Cost: $280

Guest Room Board & Batten How To

It was time to add some charm to our guest bedroom in the form of board & batten on the walls & some new (not yellow) paint. The room is big in the scope of our house at 12’x12′. It has a lovely bay window, double closet and original 100 year old ash floors. It also has amazing baseboards & trim (as does most of our house). When starting the board & batten the last thing I wanted to do was change, futz or in anyway do anything to the trim work. I wanted it to stay where it was, and do the board & batten up to it. Problem is, the baseboards are sloped and hit the wall with only 1/4″ space from the wall. This means that the material for my battens could only be 1/4″ thick, or else I’d have an unsightly overhang.Eeep…that doesn’t leave a lot of options.

Before
Before
Before
Before

These were the possibilities that I could find:

  • 1/4″ x 4 foot long poplar lattice at almost $5 each…hurmph
  • 1/4″ x 8 foot vynal trim pieces at almost $6 each…ack
  • 1/4″ thick 4×8 sheet of hardboard for $17

The hardboard was looking to be the best option, but we don’t have a table saw yet (it’s still on my wish list). So we’d have to get the Home Depot guys to cut it down for us at $1 a cut, then somehow get it home. It could work, but it also wasn’t the best case scenario…I needed to think this one out.

I then called my local lumber yard Downtown Lumber. They’re always really helpful and I thought they may have some ideas. Turns out Downtown Lumber carries 1/4″ MDF in 4×8 sheets for $15, and they make custom cuts for 50 cents each. I like using mdf much better than hardboard (as it doesn’t have that glossy surface), and the lumber store is waaay closer to our house, and easier to walk home with big lumber.
So better + cheaper + less work = happy Kristen.

So I did my math, settled on 2.5″ battens, and placed the order to have 2 mdf sheets cut into 2.5″ strips. We headed over after work to pick it up and lugged it all home along with some trim. The getting it home was an epic fail (I’m talking all of it almost falling off a dolly, practically killing a cyclist and an epic argument) dammit we should just get a car already…

So after we got the wood home, and had a few drinks to forget the ordeal, I set out sanding the edges of the mdf for a nice smooth finish, and putting a coat of Behr Premium Plus Ultra in pure white on the edges. I didn’t paint the flat part of the battens for one main reason; I was going to have to fill & touch them up anyways, and to get a smooth finish I would really need to re-paint them entirely. Rather than make myself more work. I decided to paint them once they were on the wall with a small foam roller.

I did however paint the bottom of the wall so it would save me trying to paint in between the battens (yuck). Deciding where the paint would stop (where the top rail would go) was the hardest part. The storefront is not the least bit straight or level, and when I drew a level line on the wall it looked like I had done it drunk. So we fudged it, and made it kinda sorta parallel to the ceiling and floors. We used a chalk line to line it up, then used tape to mark the line, and to keep me from painting willy nilly everywhere.

Bottom of Wall Painted White

After the paint had dried (the next day) we installed the top rail out of the 2.5″ mdf battens on the nice line we’d made with the tape the day before.

Top Rail Installed

Then the vertical battens got added. We had to custom cut each and every one, as they were all different heights. I would measure a few, and head out to the garage to do the cutting, then lug them all back upstairs, over a baby gate (that was keeping the dog from free roaming and destroying the house) and then back into the guestroom. I made countless trips up and down those stairs.

Vertical Stiles Installed

We went with 12″ of space between battens, cause, well it looked good. The front wall under the bay window the spacing is fudged so that battens framed the windows (technically they should have not two battens touching eachother, but it looks correct once its all painted).

Under the Bay Window the Spacing is “Fudged”

We did have one instance where hitting an electrical outlet was unavoidable. It was on a small wall that had 2 switches, an outlet and an a/v outlet. The battens were almost the same size as the outlets, so we placed one batten directly centered on the outlet, so we could make flush cuts against it. We then measured out our 12″ on either side. The wall is not perfectly symmetrical, but you wouldn’t second guess it.

Where we couldn’t avoid hitting an electrical outlet, we changed the spacing so that a batten would hit it square so that our cuts would be easier

To make the spacing easier, we made a spacing jig out of some old lumber, and spaced & leveled then brad nailed each batten.

Our Spacing Guide (sorry for the out of focus shot, I was trying to shoot and hold)

It went very quick, the most time consuming part being the measuring and cutting (especially if I’d measured wrong, and had to go re-cut). We labeled each batten corresponding to what wall the were working on (Left, Right, Front, Back) and gave them a letter (i.e. Left-A was the first board on the left side, whereas Right-I was the last board on the right). This made it so much easier as you couldn’t loose track of what board went where.

After we fished installing all the vertical battens, we also decided to add some horizontal battens about a foot from the top to add a bit more visual appeal, and it matches the shaker paneling on the front of the storefront. We had lots of off cuts from the vertical battens, so we cut down a bunch of 12″ battens and brad nailed them in place. (and of course custom cut ones for the odd places.)

All the Rails & Stiles Installed

Next up was to fill all the damn holes from the brad nails. I filled the nail holes with spackle, and the cracks and seams with paintable caulking. I used the spackle this time so that we could easily sand to get a perfect finish on the flat battens.

Spacking

We then added some cove moulding on top of the top rail. I was going to add a small plate rail above that as well, but that proved to be too difficult with our wonky walls. Our walls just bowed and dipped so much that there were huge gaps at points. So we decided to call it done with the cove moulding.

After all that filling, sanding and caulking, I got to painting. I cut in the edges of the battens where they met the wall. I had given one coat of paint to the battens before I had installed them, but this second coat covered all the caulking and finished the sides beautiful. I painted the flat part of  the battens using a small foam roller. I made sure not to use too much paint so that it didn’t overflow into the “board” part, and it went quite quickly. I was running extremely low on paint (had only bought one gallon) and decided to brush on my second coat. The foam roller gives a beautiful finish, but it was looking like it was going to take three coats (which I did not have enough paint for) So I switched it up and painted the entire second coat with a brush. The trick to painting a flat surface with a brush without leaving brush marks is a light touch. You want to evenly distribute the paint without pulling any back up. I paint the whole piece, and then go back over it quickly with a light brush. When the paint dries this should leave you with a nice smooth finish.

Board & Batten Painted (wall still yellow)

After it dried for a day, I went back and painted the rest of the wall with a nice medium grey, which really made the board & batten pop!

Board & Batten Complete!
Board & Batten
Odin Likes the Board & Batten

SOURCE LIST:

Materials:
2 – 1/4″ 4×8 sheets of mdf cut into 2.5″ strips: Downtown Lumber
1/2″ cove moulding: Downtown Lumber
DAP Spackle : Home Hardware
DAP Alex Plus Paintable Caulking: Home Depot
Paint (Board & Batten)- Behr Premium Plus Ultra Pure White in Satin: Home Depot
Paint (Wall) – Behr Premium Plus Ultra in Anonymous in Eggshell: Home Depot

Tools Used:
Mitre saw, measuring tape, level, chalk line, math, paint tray & rollers, brushes, sandpaper

Difficulty Level (on a scale of 1-5):

Three out of five

(the hardest part was determining the spacing)

Total Cost: $100 ($50 for the mdf & cove moulding, and $50 for the white paint. We already had the grey paint)

DIY Bedside Tables

I have been scoping around Craigslist and local antique stores for the last couple weeks trying to find some tables to turn into bedside tables for the guest room. We were using two (well worn) Ikea $10 Lack tables that we’ve had since the dawn of time, but they really needed to go. I searched and searched, but couldn’t find anything I loved. I didn’t have the budget to spend a couple hundred on new bedside tables, so I decided to make some. I headed over to The Design Confidential to look at some of their furniture plans. (They have some amazing DIY furniture plans!). I took a look through their end table/bedside table collections and spotted this plan. I instantly saw it and thought I could do a more Moroccan version of it.

The plan calls for the tables to be 18″ high, but that was a bit short for my application. I wanted to make them as tall as possible using one 4×8 sheet of lumber to make two square tables.  So I did some math and figured out that I could (just) get ten 19″ squares out of one sheet, so I headed to my local Home Depot and got a 5/8 sheet of MDF cut down to 19″ squares.

After getting my wood home I drew out a pattern for the table legs on a piece of scrap paper. I only did one side of the pattern (as its easier to just do one side, trace it onto your wood, and then flip it and trace the other side.)

Making the table pattern
Tracing the pattern onto the wood

After I traced my pattern, I cut it out of the MDF using my jig saw, sanded any rough bits, and then used that one as a pattern for the rest of my pieces. (for two tables you need a total of 8 leg/side pieces, whatever you do, don’t cut all 10 of your pieces into the leg pattern, you need tabletops too! duh!)

One table leg cut

Now follow the rest of the Design Confidential’s instructions here. Essentially you have to cut down the width of two of your table legs so that they overlap nicely. Then you stand it all up, and nail it all together. I found that using some masking tape to hold the legs together temporarily helped a lot. I just dont have enough hands to hold everything and nail it all!

Attaching table legs
The Table Assembled

After you’ve assembled everything, if you’re using MDF as your wood, I HIGHLY advise going and getting yourself some spackle. Sand all your edges so everything is nice and pretty, and then take that spackle and rub in into the mdf edges. HUH? MDF edges are rough and not as nice as the flat parts, so if you want everything to look perfect, you need to spackle those edges. Once they’re dry, sand them to a nice smooth finish, then get ready to paint. (yes I know it looks like utter crap before you’ve sanded, but just trust me.)

The rough edges of mdf covered in a thin layer of spackle

I painted the tables (inside and out) with a coat of dark grey Behr Premium Plus Ultra Paint + Primer I had laying around. Now if I hadn’t been using paint+primer, I would have put a coat of stand alone primer on first.

Tables painted a base coat of charcoal gray

After my paint dried, I mixed up a batch of DIY Chalk Paint (come back tomorrow for my DIY on this). I painted 2 coats of chalk paint in robins egg blue on the front and top of the tables. I left the inside of the legs the base colour so you got a bit more contrast with the blue.

Tables painted with two coats of chalk paint (leaving the insides of the legs the base color)

Then I sanded and slightly distressed using sandpaper and a damp cloth (to see more on my distressing chalk paint using a wet cloth check out this post). After I was happy with the distressing and smoothness of the finish, I gave it a coat of furniture wax and polished it.

Table Complete

**UPDATE** Check out this post on how to DIY your own chalk paint

SOURCE LIST:

Materials:
1 – 4×8 sheet of 5/8″ MDF – Home Depot (cut into 19″ squares by HD’s cutting staff)
DAP Spackle: Home Hardware
Behr Premium Plus Ultra paint in Cracked Pepper – Home Depot
Chalk Paint – DIY

Tools Used:
Jig saw, sand paper, compressor & brad nailer, circular saw, paper & pencil, paint brush, wet rag

Difficulty Level (on a scale of 1-5):

Three out of five

Total Cost: $30 (already owned the spackle & paint)

From Billy to Built-Ins

Our house is a three bedroom, two large bedrooms and one smaller. The smaller is of course the best choice for either an office or nursery. We wanted to plan for an office now, and if we ever needed it down the road, an easy transition to a nursery. Continue reading “From Billy to Built-Ins”

DIY Pallet Crates

If you have been being a good boy or girl, you will have read my Project Office post and you will know I have a lot to do! One of the items on the To Do list was crates for built in bookshelves. Bookscase DIY tutorial will come soon (I promise) but until then here is a sneak peak on how we made the crates to go ON the bookcase.

I was planning on sourcing some framing grade lumber and roughing it up a bit to get a worn look for my crates. Odin & I happened to be walking through an industrial area in our neighbourhood on Friday when we spied a pile of shipping pallets on the side of the road.

Stack of Pallets

I thought to myself, “self, there some rough wood, and its CHEAP rough wood”. You see, cheap is one of my favorite words. I like it so much that people often use it to describe me. So Saturday morning Odin and I took off to steal grab ourselves one of these pallets. I picked one that looked good, didn’t appear to have hobo pee or bugs on it, so I carried it home. By carried it home, I mean I walked 100 feet, rested, walked 100 more feet and had another rest all the way home. It was also a Saturday morning, and I had to walk past a hipster brunch spot in the neighbourhood looking like a crazy person. The dog happily trotted behind me wondering what on earth I was up to.

Stopping to take a break and admiring my “found” pallet

After lugging this darn thing home, swearing a few times, wishing I owned a car, and wondering what I was so damn crazy, I finally got down to work. I thought bringing it home was hard, I hadn’t yet met hard. Hard is not owning a crow bar, and trying to take out massive nails with a hammer and Mjölnir to pry and bash them apart.

Taking Apart Pallet While Trying not to Hit My Foot with a Hammer

Break time yet? GAH! This is hard work. You are probably asking right now, where on earth is El Granto? He was having a lovely day learning to drive NASCAR’s with his Dad and Brother. At about this point in time I was cursing him in every language that I know a curse word in. These include, English, French, Spanish and German. My mother would be disappointed that I don’t know any Danish curse words. The worst thing I know is how to say underwear in Danish. This was a hit when I was six…

So… I finally managed to pry apart some boards, and then bashed out the nails.

Striped Apart Pallet

As you can see the wood before sanding is…well kinda gross. It will get better, I promise. Now I put some super rough sandpaper in my palm sander, and set to work.

Getting Ready to Sand

Once I sanded everything, using the dimensions of my bookshelves, I decided on a size for the crates. I wanted them to fit in the bookcase nicely, but have a little room to slide in and out. I drew up a quick diagram on a piece of wood, and started cutting! The finished size for the crates are 29″x10″x11″ and 13″x10″x11″. I cut my front pieces 29″ long for the big ones and 13″ for the small. The sides were 8 1/4″ and each crate was 3 boards high. I cut the boards to length on the miter saw, and used scrap pieces of 1×2’s as corner braces. I attached the front panels to the corner supports using brad nails. I spaced the corner supports 5/8″ in from the edge to allow space for the sides to fit flush.

One Front of Crate Assembled

I assembled both the fronts, then attached them to the sides with more brad nails. I then traced a bottom for the crate onto some extra hardboard we had laying around the garage. I cut out the hardboard with the circular saw, and nailed it to the bottom of the crate.

Voila! Crate!

The wood is all different thickness, and I didn’t worry about having everything match perfectly. It just adds to the distressed look. After I had assembled it, I took the palm sander to it again making sure there were no sharp corners or splinters. There, I was done! It only took me 3 hours to make one crate. Wait, what, I need four more of these? DAMMIT! I better get back to work. I sanded and cut the wood to length for one more crate, but I ran out of brad nails. Uck. So I waited for El Granto to get home from his NASCAR adventure and then headed to Canadian Tire to pick up more nails, and some felt furniture sliders for the bottoms of the crates. We also stopped and pilfered one more crate on our way home, which I made El Granto carry, and he cursed me in the same fashion that I had cursed him earlier. Once I got home, a soft couch and a cold drink sounded better than doing more work, so I gave up, and left it for Sunday.

Sunday morning, we got all ready to start work (this time with El Granto in tow). When we went outside our neighbours were putting up a big glass panel on their amazing deck, and asked for some muscle. El Granto went to help, and I got back to work making more crates. El Granto’s work conveniently consisted of standing holding a piece of glass for an hour, then being rewarded with a plethora of yummy beverages. Of course he preferred doing this to helping me make crates…so once again I was bustin my ass alone. El Granto did stop in to help me take apart the second pallet (it’s much easier to watch him then to do it myself.) I proceeded to make one more big crate, and three little ones.

Small Crate

The little ones are cute. Like a puppy version of a crate. I finally finished all five of my crates, and stood back to appreciate my giant stack-o-crates.

Stack-o-crates!

Some of the wood turned out really cool. The ones that look all spotted were really really rough boards, that I sanded and sanded and sanded and they came out all spotty! I also really like the boards with the rough saw marks. I thought I may have to distress the crates more, but I think they look fairly worn. They look like driftwood almost. I was on the fence with staining them, but we like them just the way they are, so we’ll leave them as is for now. They do need some hardware, I am waffling between shiny fancy nickle handles (that I am using elsewhere in the room) or sticking with rustic and using some rope, either as a handle, or making small monkey’s fists and using them as pulls. What do you think?

Sneak Peek of a Crate in the Office

So what do you think? Free crates, were they a pass or a fail?

UPDATE!

My idea to use pretty polished handles on my crate was overruled by El Granto, my Mom, our neighbours, my co-workers and the garbage man. So rope handles it is!

We checked Rona, and their rope was too big, Home Depot had even bigger rope and some smaller rope. We went with the small one. In hindsight, I wish it was a bit chunkier. Will be keeping an eye out for some bigger rope. Also, check out the completed bookcase here.

SOURCE LIST:

Materials:
Wood Shipping Pallets : side of the road
1×2’s: Pile-o-wood in my garage
1/8″ hardboard: My garage
Brad Nails: Canadian Tire
Sandpaper: Canadian Tire
Felt Furniture Pads: Canadian Tire
Rope: Home Depot

Tools Used:
Maul, Hammer, Circular Saw, Miter Saw, Measuring Tape, Compressor & Brad Nailer

Difficulty Level (on a scale of 1-5):

Four out of Five

(cause damn those pallets were heavy!)
Total Cost: $7 for the rope & furniture pads