DIY Network

Outdoor Workshop From "Wasted Spaces" episode DWSP-111

(Continued from page 1)

Deck Panels

1. When building multiples of anything, a jig is helpful to ensure accuracy in each piece as you build. A jig was built by fastening 1" strips to a piece of plywood that matched the outside dimensions of the panels.

2. Use 2"x6" cedar planks to construct each panel. Start by cutting a perimeter of cedar and setting that into the jig face down.

advertisement

	After the grid pieces are fastened together, measure the openings to determine how large the deck panels need to be. It's best to leave a 1/4" to 1/2" gap all the way around the panel to make it easier to lift.
	Each panel should drop right into place. Because the center is cut at an angle, the panels can be rotated to achieve a pattern.

3. Cut the center 2"x 6" pieces at an angle. Router the edges with a 1/4" roundover bit for a more finished look. Place those pieces within the frame, again, face down.

4. Four strips of pressure treated plywood, screwed to the back, will hold the cedar in place.

5. It's important that there are at least two screws in every end of the cedar to keep them securely in place and eliminate any pivoting.

6. Use a collated driver, but any screw gun and 2-1/2" exterior screws will work.

7. Repeat the process for each panel. The number of panels you need to build will be determined by how large your space is and how large your panels are.

Setting Panels

1. Set the panels into the grid.

2. Make sure to keep your fingers clear!

3. You can always change the pattern or replace a panel if one gets damaged.

There were two openings originally added for windows. However, the garage no longer needs windows and the holes are massive. Building window boxes to slide into the hole and provide storage is a great idea!

Window Boxes

1. Measure the opening to determine how large the box needs to be to fill the hole.

2. Cut birch plywood to size on the table saw and assemble them with simple butt-joint construction using wood glue and nails. Each box has four sides, a back and a shelf.

3. Tim's house is rustic and he had rustic salvaged lumber laying around so we incorporated those into the shutters for the window boxes. If you want a more finished look, use birch plywood that can be painted or stained.

4. Install the boxes onto the wall before attaching the doors. To install the boxes into the empty window frames, use masonry screws and screw them right through the side of the box and into the concrete block.

5. Each shutter door is made from three pieces of salvaged lumber held together by two horizontal braces.

6. After the boxes are installed, put two hinges on each door and attach them.

7. Use a simple hook and eye latch to keep the doors closed.

Whether you're working in your garage or in an outdoor shed, a sturdy work surface is a must. For Tim, that workbench had to be rustic. The workbench was framed with rough sawn 2x4s and cut barn wood for the top.

Rustic Workbench

1. Determine the height of your workbench. Tim is tall, so his workbench is tall. There are no set measurements for this so find a height you like and build your workbench to match. Factor in the height of the top and your framing and cut your legs to length.

2. Frame the top. Again, you're making this for you so decide how wide you want your work surface to be, and cut to that. The lumber used to cover the top was 12" wide, so we decided on two pieces together for an overall width of 2'.

3. Screw the top frame together with 3-1/2" screws. Add center supports to fasten the top to.

4. Screw the legs you cut into the corners of the top. Use a level to make sure they are plumb and add angled braces for extra support. After the legs are attached, flip the workbench over so you can put the top on.

5. Secure your top material with screws. This is where the center supports come in to play. Make sure the material is fully supported as it spans the length of the workbench.

6. A lower shelf is optional. If you want to add one, use the same framing material to build a shelf half the width of the top. Cover it with the material you used on top and screw it down the same way.

1 | 2

RESOURCES :

Benjamin Moore Paint
Website: www.benjaminmoore.com

Klein Tools
Website: www.kleintools.com

Delta Woodworking
Website: www.deltaportercable.com

Porter-Cable Tools
Website: www.deltaportercable.com

Western Red Cedar Lumber
Website: www.wrcla.org