This tutorial makes more sense if you watch the included video I made as well. I built this bike storage/display cabinet so I could get my bike out of the garage and out on display so it can serve as the functional piece of art that I believe bicycles are. Here are a few of the materials I used building this project:
Track Saw - https://bit.ly/2OqEWSh
Brad Nailer - https://amzn.to/2TCZR5e
Edge Square - https://amzn.to/2TEbdWO
Digital Angle Finder - https://amzn.to/2TEbdWO
Spindle Sander - https://amzn.to/2TEbdWO
Kreg Pocket Hole Jig - https://amzn.to/2TEbdWO
Kreg Hinge Jig - https://amzn.to/2TEbdWO
Hinges - https://amzn.to/2TEbdWO
Flush Trim Saw - https://amzn.to/2TEbdWO
Chisels - https://amzn.to/2TEbdWO
Incra Edge Rule - https://amzn.to/2TEbdWO
Screwdriver Kit - https://amzn.to/2TEbdWO
Forstner Bits - https://amzn.to/2TEbdWO
Tape Measure - https://amzn.to/2TEbdWO
Square - https://amzn.to/2TEbdWO
Angle Grinder - https://amzn.to/2TEbdWO
Miter Saw - https://amzn.to/2TEbdWO
Drills - https://amzn.to/2TEbdWO
Sander - https://amzn.to/2TEbdWO
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Step 1: Breaking Down 1 Sheet of Plywood
For this project I'm using a 5x5 sheet of Baltic Birch plywood. I was able to build almost the entire cabinet from this one sheet. I had to use a leftover scrap piece for the center divider. You can adjust materials for the size of your bike, and the type of wood or plywood you want to use. This project would look great in many different configurations and wood species.
- Break the plywood down into 4 pieces that are 47" x 13" and 4 pieces that are 13" x 13".
Step 2: Panel Glue-Up, Bevels, Rabbet
1. Cut two of the 47" x 13" panels in half .
2, Using one of the 13" panels to create a dado, glue up the panels cut in half to another 47 x 13 inch panel. This will create a groove on the top and bottom for the center divider. It's important to mark out lines so you can line these up perfectly later. Also note how I used the fence of my table saw to keep everything in alignment during the glue up.
3. Shoot in a few brad nails to keep everything holding together and lined up. Just make sure to inset these several inches from any corner so you don't cut into them when creating the 45 degree bevels.
4. Glue up 2 pairs of 13 x 13 inch panels in the same fashion.
5. Once the glue is dry cut in 45 degree bevels on the ends of the four panels. Its very important to cut equal lengths off the two longer panels so the dado remains aligned.
6. Cut in a 1/8" rabbet on the back of each panel to accept a backer board in a later step.
Step 3: Cutting Bike Storage Recesses
1. Measure the length of your cabinet, and how that relates with your specific bike. The following measurements specifically fit my bike. I used my empire square to set the distance and make sure my measurements were level. The square is 5 1/4 inches tall on its short side which was the perfect depth to inset the wheels. The distance between my wheels was a little less than 17 inches. This meant I needed to cut in 15 inches on either side. See diagrams and photos for further information.
2. I made a template out of cardboard to test my measurements before cutting into the panels. I HIGHLY recommend doing this before cutting.
3. Mark out your tire cut outs, and drill the end of each recess out with a 1 1/4" forstner bit.
4. Cut the recesses with a bandsaw, jigsaw, or circular saw.
5. Clean up the cut outs with a sander.
Step 4: Cabinet Glue-Up, Reinforcement, Center Divider
1. Glue up the cabinet along the miters making sure to check for square often. I used a band clamp, pipe clamps, parallel clamps, and corner clamps to get everything into alignment.
2. Now taking precise measurement for the center divider sneak up on this cut untill you have a fit that is tight, but allows you to hammer the center divider into the dados. Add wood glue before doing so.
3. Check for square, and clamp into place.
4. To reinforce the miters I drilled out holes with a 3/8" bit. I added screws, and plugged the holes with dowels. did two screws per end per face, and offset them so the screws wouldn't run into each other.
5. Plug the holes with 3/8" dowels and trim flush.
Step 5: Making & Installing the Doors
I made the doors from Red Cedar, but you can use any wood species you'd like. I really like the contrast of the cedar with the baltic birch.
1. Rip your boards to 6 inches wide. Crosscut them to about 24 inches long or what ever oversized dimension you need for your size cabinet.
2. Edge glue the door panels.
3. This step is optional. You can avoid this by using 3/4 inch material. I planed my 4/4 cedar down to 3/4 inch. This gave me consistent size doors, and saved time sanding the glue seams.
4. Measure the door openings and cut the doors with about a 1/6" inch reveal all the way around. Sneak up on the cuts.
5. Attach the hinge hardware. I used Blum inset hinges.
Step 6: Making & Attach the Door Handles.
For door handles I wanted to stick with a bicycle theme. I went to a local bike shop and bought 2 small, cheap chain ring sprockets. Why buy two when I was going to cut them in half? The ones I purchased were not symmetrical. If you can find symmetrical ones, or don't mind non symmetrical you can cut one in half.
1. Mark out the center of the sprocket. Cut in half with an angle grinder and cut off wheel.
2. Mine sprocket had three holes that were perfectly placed for attachment. I drilled them out wider to accept the 1/4-20 bolts I used. I marked out the location on the doors and drilled matching holes. I drilled a recess on the back of the door for the nuts that would hold the bolts so they could sit flush.
Step 7: Finishing, Backer Board, Legs, Final Assembly
1. For Finish I added 4 coats of Minwax Polycrylic. This is my favorite finish to baltic birch because it maintains the blonde natural color of the plywood without yellowing.
2. Attach four legs. I used 13" steel legs I got from Kit & Co (https://www.kitn.co/)
3. Cut a backboard out of 1/8" inch plywood to fit in your cabinet. I painted the inside face of the backer board this turquoise blue that adds a pop of color when the doors are opened.
4. Reattach the doors and hardware. To create door stoppers I used a 1/4" nut and a screw. After that this bike cabinet is done!
Step 8: All Done!
Thats it! Thanks for checking it out, and if you build this make sure to tag me on IG @jonnybuilds or email me a pic to email@example.com
Remember the video provides even more detail, so make sure to check it out.
Runner Up in the