Build modern-style kitchen storage trolley from plywood boxes

This pigeonhole unit is good for storing art equipment or being used as a dining server. It’s comprised of nine individual boxes made from 9mm plywood, butt joined using yellow PVA adhesive and 15mm brads driven with an electric nailer or by hand.

 

An outside joining layer of the same plywood thickens the walls, adding strength and stability. Have it cut to size by the supplier for fast, accurate assembly. Plywood and other components required for this project are available from Builders Warehouse, or can be ordered for you.

USING ALUMINIUM
Aluminium flat bar positioned  along the edges contrasts with the plywood and disguises the joins. Cut the aluminium using a mitre saw with a metal cutting blade, or use a timber cutting blade lubricated with a spray of WD-40.

 

FINISHING THE PLYWOOD
Apply two coats of clear shellac using a fine natural brush. Shellac dries quickly, so try to avoid drips or blotches as there’s no time to wipe up errors. Finish with a protective layer of beeswax furniture polish.

Using Adhesive

White and yellow woodworking adhesives are water-based polyvinyl acetate glues, or PVAs.
Yellow glue has a shorter drying time than white, usually up to 10 minutes, and keeps its colour when dry, while white PVA dries clear. Cross-linking PVAs have greater inherent holding powers, as the strands interlock when bonding, improving the strength of the join.
For a project like this kitchen trolley, where a mixture of strength and speed is required, use a yellow cross-linking PVA.

 

CUTTING LIST
(measurements in mm)
 
Part                         Size                   No.
FIJIAN CEDAR PLYWOOD
Box tops and bases           386 x 380 x 9.5        18
Base box sides               386 x 330 x 9.5        6
Mid box sides                386 x 140 x 9.5        6
Top box sides                386 x 200 x 9.5        6
Base box backs               380 x 349 x 9.5        3
Mid box backs                380 x 159 x 9.5        3
Top box backs                380 x 219 x 9.5        3
Base and top layer           1140 x 396 x 9.5       2
Side layer                   846 x 396 x 9.5        2
Back layer                   1159 x 846 x 9.5       1
Top back inner               1140 x 100 x 9.5       1
Top side inner               386 x 100 x 9.5        2

ALUMINIUM FLAT BAR
Front side                   846 x 20               2
Front horizontal             1119 x 20              4
Base row vertical            330 x 20               2
Mid vertical                 140 x 20               2
Top vertical                 200 x 20               2
Top rear edge                1159 x 20              1
Top side edge                407 x 20               2

ALUMINIUM ANGLE
Rear vertical edge           848 x 20 x 20          2