Trophy Case
Project 1: Trophy Case
Materials & Tools:
Materials & Tools:
- 3 – ¾˝x4x8 Furniture Grade Plywood
- 1 – ¼˝x4x8 Furniture Grade Plywood
- 1 – ¼˝x4x4 (1/2 sheet) Furniture Grade Plywood
- 3 – 1˝x4˝x 8ˊ Clear Pine
- 11 – 1˝x2˝x 8ˊ Clear Pine
- 1 – 4˝x4˝x 14˝ Douglas Fir (you only need a length about 14˝ long)
- 4 – ½˝ Lap Overlay Self closing Hinges
- 2 – Cabinet Door Knobs
- 1 Quart Stain
- 1 Quart Poly
- Table Saw, Miter Saw & Circular Saw
- 18 Gauge Nail Gun W/ 1¼˝ - 2˝ 18 Gauge Nails
- Drill W/ Countersink Bit & 1¼˝ - 2˝ Wood Screws
- Orbital Sander W/ 150 – 220 Grit Sandpaper
- Yellow Wood Glue & Wood Putty
- Kreg Pocket Hole Jig W/ Screws
Cut List:
¾˝ Plywood (All the #’s listed below are in inches)
Main Case
- 2 @ 23¼ x 47 Top & Bottom Panels (45˚ both ends of each)
- 2 @ 23¼ x 33 End Panels (45˚ both ends of each)
- 1 @ 23¼ x 31½ Middle Divider (square both ends)
- 4 @ 23¼ x 22⅜ Shelves (square both ends)
- 1 @ 11¼ x 47 Top & Bottom Panels (45˚ both ends of each)
- 2 @ 11¼ x 48 End Panels (45˚ one end of each & square the others)
- 3 @ 11¼ x 45½ Shelves (square both ends)
1x2 Clear Pine
Face Trim – Main Case
- 2 @ 47⅛ Top & Bottom Rails
- 2 @ 30¾ Right & Left Side Stiles
- 4 @ 20⅞ Shelf Stiles
- 1x4 Clear Pine
- 1 @ 2¼ x 30¾ Middle Stile (Cut piece to length then rip to 2¼)
1x2 Clear Pine
Face Trim – Top Case
- 1 @ 47⅛ Top Rail
- 2 @ 46½ Right & Left Stiles
- 3 @ 44 Shelf Rails
¾ x ¾ Clear Pine
Nailers – Top & Bottom Case
• Rip three full lengths of 1x2 in half so you end up with ¾ x ¾.
- 16 @ 23 Nailers for Main Case
- 10 @ 11 Nailers for Top Case
¼˝ Plywood
Back Panel
- 1 @ 46⅞ x 84⅞
- 2 @ 17 x 27
1x4 Clear Pine
Door – Stiles & Rails
• Rip the remaining 1x4’s to 3˝ before cutting them to length.
- 4 @ 16½ Door Rails
- 4 @ 32½ Door Stiles
4x4 Douglas Fir
Legs
- 4 @ 3˝
Step by Step
Building the Main Case...
- Cut the main case panels to size according to the cut list. Lay the middle and two end panels flat on a table lined up edge to edge. With a framing square mark your shelf locations on one of the panels. Run these lines all the way across all three panels. Flip the middle panel over and mark the other side the same way.
- Attach the ¾˝ x ¾˝ nailers to the panels, using wood glue & 18 gauge nail gun W/ 1¼˝ nails. Line each nailer up with the lines you drew and attach them on the bottom side of the line. The Middle panel will get the same amount nailers on each side. Attach nailers to the top and bottom edges of each panel as well. For the end panels, attach the nailers to the bottom inside edge line of the 45˚ cut. For the middle panel, attach the nailers to each side, flush with top and bottom edges. Note: These nailers serve two purposes; they hold up the shelves & help to connect the panels.
- Connect the four panels, using wood glue & 18 gauge nail gun W/ 1¼˝ nails. Line up the 45˚ miters then glue & blind nail each corner together. You are effectively forming a rectangle – the main case. Note: Blind nailing means that instead of nailing through the top surface of one panel into another to connect them, you instead, nail from underneath - thru the ¾˝ nailer into the bottom of the panel your connecting to. This keeps the top surface of your case free of nail marks.
- Cut the shelf panels for the main case to size according to the cut list. Slide the shelves into the main case so they rest on the nailers. Check for fit, they should be sung. If the fit is good, attach them using wood glue and the blind nailing method. Make sure that the front edges of the shelves are flush with the front edges of the case.
- Cut the 4x4 legs to size according to the cut list. Attach them to the bottom of the case at the corners. Keep each leg lined up and flush with a corner. Attach the legs using wood glue & 18 gauge nail gun W/ 2˝ nails. For the legs, nail through the top of the ply into the leg. Fill the nail holes with wood putty.
Building the Top Case...
- Cut the panels to size according to the cut list. Lay the two end panels edge to edge and mark the lines for your shelves. Attach the 11˝ nailers to the lines and the ends of the panels as you did in step #2 above.
- Connect the two end panels to the top panel by blind nailing the corners together. Repeat the process in step #3 above. Note: The Top Case does not have nor does it need a bottom panel. The bottom nailers will act as the attachment points to the Main Case.
- Cut the shelf panels for the top case according to the cut list. Slide these shelves into the top case resting them on the nailers. If the fit is good, go ahead and attach them in the same manner as you did in step #4 above.
Attach the Top Case to the Main Case...
- Set the top case onto the main case so that the ends of the end panels line up flush with sides & back edge of the main case. Once your satisfied with the fit, connect the two with wood glue & 1¼˝ wood screws. Drive the screws through the nailers into the top panel of the main case. Make sure to pre-drill & countersink the nailer before driving in the screws.
Attach the Back Panel...
- Cut the back panel (¼˝ ply) to size according to the cut list. Attach this panel to the back of the case using the 18 gauge nail gun W/ 1¼˝ nails. Start in a corner and square the case to the panel as you go. Continue nailing all the way around the edge and into the back of each shelf as well.
Attaching the Face Trim...
- Cut the top & bottom rails according to the cut list. Attach these rails (top edge of the top case, top edge of the main case & bottom edge of the main case) using wood glue & the 18 gauge nail gun W/ 1¾˝ nails. Face nail the trim to the edge of the plywood. Try to limit the number of nails you use. Note: Keep the top edge of the trim flush to the top edge of the plywood your attaching it to.
- From this point on, you can refer to the cut list, but measure each piece of trim before cutting it to fit. Measure, cut, then attach all of the stiles (upright trim) next. Finish the trim by cutting & attaching all of the shelf rails. Note: All of the trim is 1½˝ wide (1x2) except for the middle stile on main case. This piece should be 2¼˝ wide. See cut list.
- Putty & sand all of the trim.
Making the Doors...
- Cut the door stiles & rails to size according to the cut list. Make sure the cross cuts you make on the rails (16½˝) are exactly 90˚.
- Cut the ¼˝ plywood door panels to size according to the cut list.
- Using the table saw W/ the blade height set to ⅜˝, run a groove down the center of one edge of all the stiles & rails. This groove should be ¼˝+ wide. Mark the center of one of the ends of one of the stiles or rails, and then line this mark up with the blade of the table saw. Now move the fence over against the piece of wood. Now you’re ready to rip. This ⅜˝ x ¼˝ groove or dado you create will eventually accept the ¼˝ door panel. Note: If you don’t have a ¼˝ dado, you will have to make a few swipes through each piece to get the width you need.
- Using the Kreg pocket hole jig W/ pocket hole screws, join one of the 16½˝ rails to two of the of the 32½˝ stiles. Place the rail between the stiles so the long outside edge of the rail is flush with the ends of stiles. Make sure the dodo’s are all facing in. Clamp the three pieces together and use the pocket hole jig to drill the holes from the stiles into the ends of the rails. Glue the joint and drive in the pocket screws. Repeat this same process to the other set of stiles & rail.
- Slide the door panels into the grooves of each partially finished door frame. If the door panels don’t slide in fairly easily, just sand down the edges until they do. The fit should be fairly snug.
- Tap on the remaining rail until it rests snugly between the two stiles. Flush up the rail with the stiles, and then join them the same way you did in earlier.
- Check the fit of the doors on the front of the main case. If satisfied with the fit, sand then stain & poly the doors.
- Attach the hinges to the doors W/ the supplied screws. Now you can attach the doors to the main case.
- Attach the door knobs to the doors and you’re done.