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Sports Garage Makeover This all-star garage makeover is in a league of its own. From "Wasted Spaces" episode DWSP-202

(Continued from page 2)

Sports Storage

The hanging shelf will keep seldom-used items out of the way, but what about the sports equipment, school backpacks and other must-haves the Caldwells need at their fingertips? Karl and Jill build a custom caddy to corral balls and other sports equipment with flexible bungee cords.

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	Precise measurements and cuts make all the difference when building this fun sports caddy.
	Figure A
	Figure B
	Figure C
	Figure D

Building the Ball Caddy

Safety Alert: Always wear eye protection and use caution when working with a power saw or other power tools.

1. Measure and cut a piece of 1 /4" plywood to 5 feet by 3-1/2 feet. This will form the back of the ball caddy.

   Tip: Cut on the waste or scrap side of the cutting line to keep from over-cutting the piece.

2. Measure and cut 3/4" birch plywood for the outer box of the ball caddy (figure A):
   
   (4) 3-1/2' x 2' pieces for the top, bottom and shelves
   (2) 5' x 2' sides

3. Lay out the 5-foot pieces of plywood and mark the locations for the shelves. Draw a straight line across the inside surface of the side pieces where the shelves will sit, then draw a corresponding line on the outside surface of the side pieces at centerline for each shelf. This will serve as a nailing guide. Karl kept a large space between the two shelves for the ball-storage area.

   Safety Alert: Always wear eye protection and use extreme caution whenever using a nail gun.

4. Start assembling the caddy: Stand one side piece on its side and line up one of the shelves. Use glue and nails to attach the shelf, making sure to follow the marks and keep the shelf straight. Drive the first nail at the bottom to hold the shelf steady, then nail from the top down (figure B).

5. With the first shelf attached to one side of the caddy, align and attach the other side to the shelf. This will help hold the piece steady during the rest of the assembly.

6. Attach the other shelves, top and bottom of the caddy in the same manner, taking care to follow the marked lines and keep the shelves straight.

7. Nail the 1/4" plywood backing to the back of the project (figure C). This will help keep items in place and will stabilize the unit.

8. Cut pieces of 1" facing lumber to fit the front edges of the sides, top, bottom and shelves of the caddy. Cut an extra "shelf size" piece of facing lumber, plus a piece 3-1/2 feet long. Set these extra pieces of facing lumber aside; they will be used to help anchor the bungee cords for the ball-storage area.

9. Use a finish nailer to attach facing lumber to the front edges of the top, bottom, sides and shelves.

10. To create the ball-storage area, measure and make marks at 4-inch increments along the front edge of one shelf. Use a Forstner bit to drill holes at these points to accommodate bungee cords (figure D).

11. Measure, mark and drill identical holes in the 1-inch face of the longer piece of facing lumber remaining. Use nails to attach this piece of lumber above the shelf that forms the bottom of the ball-storage area. Attach the piece so that there will be room to attach a regular piece of facing lumber in front of it to match the shelves, and be sure to leave enough space above this piece for balls to easily pass through into the storage area.

12. Attach the final piece of facing lumber in front of the drilled piece, covering it the same as the shelves.

13. Sand and paint the caddy.

14. To help protect the caddy from the elements in the garage – and from accidental kicks as the Caldwell boys grab their equipment – Karl built a level platform out of pre-treated, water-resistant lumber and painted it to match the caddy.

	Make sure there's enough "give" in the cords to give access to the sport balls.
	The final caddy hits a home run with the active Caldwell family.

Stringing the Bungee Cords

1. Move the ball caddy into place against the wall.

2. Tie a knot in one end of the bungee cord. Thread a washer through the cord so that it rests on the knotted end.

3. Pull the free end of the cord down through the first hole in the drilled facing lumber. Pull the cord down through the corresponding hole in the shelf, lightly stretching the cord.

4. Thread the cord up through the next hole in the shelf, then up through the corresponding hole in the lumber above. Continue to feed the cord through the holes to create the bungee cord "wall" at the front of the storage bin.

5. When the cord is near the end, thread a washer over the end of the cord. Gently pull the cord to create enough tension to hold the balls in the storage bin – but keep the cord loose enough so that people can pull balls out between the cords. Tie off the bungee cord with a figure eight or granny knot to hold it in place.

6. Repeat the process with additional bungee cords until the front of the ball-storage area is completed.
   
   
   

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   ALSO IN THIS EPISODE:
   	Sports Garage Makeover