DIY Network

Storage Hutch Storage is added to a china hutch. From "From Junky to Funky" episode DFJF-302

Host Samantha Gleisten helps a homeowner turn an old china hutch into a place for storage and organization for his office

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Materials:

china cabinet with 4 lower drawers
tracing paper
2-3 yards fabric
3/4" plywood
2 adjustable file hanger sets
wood glue

Figure A

1. Unscrew the top of the hutch from the bottom half (figure A). Remove the doors, handles, and hinges for easier painting later on. Remove the fabric backing in the rear of the upper half.

2. Carefully remove and set aside the interior trim that held the glass pane in place. Use a thin putty knife to gently lift the trim from the frame--starting right next to a nail (look for a nail hole) near a corner. Note: Go slow and avoid excessive force, which could break the thin trim.

3. Once the trim is removed, pull out the nails with pliers.

4. Remove the drawer slide from the top drawers, and then set aside.

5. Use a hammer and chisel to remove the hardwood center guide strip and bracing triangles. Set the guide strip aside.

6. Drill through the center of the bottom of the top drawers and the center supports between the top and bottom drawers using a 3/4 inch paddle bit, and then cut outward with a jigsaw, making stress cuts in a star shape.

7. Use a hammer to break and pull out the bottom of the drawer, and then remove the particle board center and supports.

8. Measure and cut four 3/4 inch plywood "splints" that will cover the inside drawer ends and span from the top of the top drawer to the bottom of the drawer drawers.

9. Stand two paired (top and bottom) drawers on their side, aligned as they would be in the closed position. Tape a piece of tracing paper onto the upward facing end, and then trace the profile curve from the front inside faces. Cut out this paper template, and then transfer to 3/4 inch birch plywood.

10. Cut the template from the birch plywood using a jigsaw and band-saw.

Tip: Cut the plywood larger than needed, and then make adjustment cuts until it fits.

11. Glue and clamp the splints to the insides of the drawer pairs.

12. Pre-drill and counter-sink one inch screws from the outside of the drawer to hold the splints in place.

Figure B

13. Reuse the center drawer slide and guide from the top drawer to reinforce the new combined drawer. Note: Each double-drawer will ultimately have two slides below it (figure B), and two guide strips to slide on. Screw down the reinforcement slide perfectly parallel to the existing slide by measuring four inches from each end.

14. Cut a notch using a jigsaw on the bottom of the drawer to accommodate the additional slide. Screw on the reused drawer guide with reused screws.

15. Some clean up sanding may be needed where the drawer's bottoms once were, and to round-over the tops of the new plywood splints.

16. Lightly sand all the exterior surfaces of the lower half, as well as the interior and exterior surfaces of the upper half with fine sandpaper to rough-up the existing finish and aid in the new paint adhesion.

	Figure C
	Figure D

17. Prime and paint (figure C) the exterior of the bottom, and interior and exterior of the top. A light sanding with super fine grit sandpaper may be required between the first and second coat of paint to guarantee a smooth finish.

18. Replace the glass, and reuse the trim removed in step one. Nail 3/4 inch brads through the existing holes in the trim.

19. Attach fabric to the back/interior (figure D). Cut the fabric slightly larger than the surface to be covered.

20. Starting from the center and working outward, use spray adhesive to attach the fabric to the back of the unit.

21. Using a razor knife, cut the excess fabric from around the perimeter.

Project Cost:

China hutch: $150
Plywood: $20
Fabric: $20
Materials: $15

Total: $205

RESOURCES :

The Brown Elephant
Website: www.howardbrown.org/hb_brownelephant.asp