More in Remodeling
Customizing the design to the closet makes the most of the available space. For this project, the sorter measures 60" x 34" x 20". The overall design is a large plywood box with a shelf across the center. Shelf supports also serve as dividers, spaced to accommodate baskets and bins.
Cut 3/4" birch plywood to size for the box frame, shelves, vertical supports and top.
Use wood glue and a finish nailer to assemble the main box, making sure to square up all corners. Add the shelf and dividers/supports, also securing with wood glue and nails.
Tip: Flip the box upside-down to assemble the shelf and supports. This will make it easier to drive nails straight down into the supports.
The design calls for holes in the top of the sorter for depositing laundry. Use a straight edge and carpenter's pencil to outline the holes on the top of the sorter.
Tip: To give the holes rounded corners, line up a paint can on the rectangle and trace around the can's curve.
Either drill a large hole or make a plunge cut with a circular saw inside the lines for the sorter holes, then use a jigsaw to make the cuts (Image 1). Use a router with a round-over bit to smooth out the edge of the hole, then sand the holes (Image 2). Routing and sanding will help keep clothing from catching on splinters
Use a brad nailer to add 3/4" trim to all of the raw plywood faces on the front of the piece. Prime and paint as desired.
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