DIY Network

Trophy Case Take a look at some more manly cabinet projects from Man Caves. From "Man Caves" episode DMCV-112

The trophy case is built to fit perfectly within the niche. Stainless-steel panels are added to the front of the cabinet doors to match the 1950s-inspired chair rail and decor.

This wooden cabinet is built to fit a niche and display awards and trophies.

Materials:

three sheets of 3/4˝x4x8 furniture-grade plywood
one sheet of 1/4"x4x8 furniture-grade plywood
one sheet of 1/4˝x4x4 (1/2 sheet) furniture-grade plywood
three pieces of 1˝x4˝x 8’ clear pine
11 pieces of 1˝x2˝x 8’ clear pine
one piece of 4˝x4˝x 14˝ Douglas fir (you only need a length about 14˝ long)
four 1/2˝ lap overlay self-closing hinges
two cabinet door knobs
one quart stain
one quart polyurethane
table saw, miter saw and circular saw
18-gauge nail gun with 1-1/4˝ - 2˝ 18-gauge nails
drill with countersink bit and 1-1/4˝ - 2˝ wood screws
orbital sander with 150 – 220 grit sandpaper
yellow wood glue and wood putty
Kreg pocket-hole jig with screws

Cut list:

3/4˝ plywood
Main case
two – 23-1/4" x 47" top and bottom panels (45˚ both ends of each)
two – 23-1/4" x 33" end panels (45˚ both ends of each)
one – 23-1/4" x 31-1/2" middle divider (square both ends)
four – 23-1/4" x 22-3/8" shelves (square both ends)
Top Case
one – 11-1/4" x 47" top and bottom panels (45˚ both ends of each)
two – 11-1/4" x 48" end panels (45˚ one end of each and square the others)
three – 11-1/4" x 45-1/2" shelves (square both ends)

1x2 clear pine
Face trim – main case
two – 47-1/2" top and bottom rails
two – 30-3/4" right and left side stiles
four – 20-7/8" shelf stiles

1x4 clear pine
Face trim – main case
one – 2-1/4" x 30-3/4" middle stile (cut to length then rip to 2-1/4")

1x2 clear pine
Face trim – top case
one – 47-1/8" top rail
two – 46-1/2" right and left stiles
three – 44" shelf rails

¾" x ¾" clear pine
Nailers – top and bottom case
Rip three full lengths of 1x2 in half so you end up with 3/4" x 3/4".
sixteen 23" nailers for main case
ten 11" nailers for top case

1/4˝ plywood
Back panel
one – 46-7/8" x 84-7/8"
Door panel inserts
two – 17" x 27"

1x4 clear pine
Door – stiles and rails
Rip the remaining 1x4s to 3˝ before cutting them to length.
four – 16-1/2" door rails
four – 32-1/2" door stiles

4x4 Douglas fir
Legs
four – 3˝

Building the main case:

1. 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.

Figure A

2. Attach the 3/4˝ x 3/4˝ nailers to the panels using wood glue and an 18-gauge nail gun with 1-1/4˝ 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 (figure A). These nailers serve two purposes; they hold up the shelves and help to connect the panels.

3. Connect the four panels using wood glue and an 18-gauge nail gun with 1-1/4˝ nails. Line up the 45˚ miters then glue and blind nail each corner together. You are effectively forming a rectangle – the main case. (Note: Blind nailing means nailing from underneath through the 3/4˝ nailer into the bottom of the panel your connecting to, instead of, nailing through the top surface of one panel into another to connect the pieces. This keeps the top surface of your case free of nail marks.)

4. 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 snug. 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.

Figure B

5. 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 and an 18-gauge nail gun with 2˝ nails. For the legs, nail through the top of the plywood into the leg. Fill the nail holes with wood putty (figure B).

Building the top case:

6. 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.

7. Connect the two end panels to the top panel by blind nailing the corners together. Repeat the process in step 3. Note: The top case does not have a bottom panel. The bottom nailers will act as the attachment points to the main case.

8. 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.

Page  1 | 2