Expert: Jamie Yocono - 1/19/2010

Question
Having recently retired I would like to build some custom storage cabinets for my garage. I haven't worked in wood since I was a kid but always loved it.

I'm discovering that due to expense and availability you can't just build your components from the most obvious materials but have to design from less than optimal materials such as particle board.

I've decided to try 3/4" melamine for my caucuses and doors using frameless, euro design doors.  My question involves the use of softwoods, such as fir, for structural supports such as nailers to the wall.    
 
Red Oak and Poplar go for $3.50 to $3.80 per bf around these parts and I can easily add one or two extra hidden nailer cross members behind the back our of fir to spread the load. BTW, I'm building 3 boxes each 11" deep, 24" w x 67" tall to be mounted side by side above the washer and dryer.

It seems logical to me that you can overcome the 'softness' of fir by beefing up the supports with more cross members and using wide washers on your lag bolts.  

Answer
Hi Mike,

I'm not exactly sure what you're asking here - but I think you're wanting to know about using solid wood components with melamine cabinets. I use Poplar all the time for hanging rails. You're right - wide washers will work well to keep the screw and bolt heads from pulling through the soft wood.

But there's a better, and more cost effective solution.

Cabinet manufacturers also use plywood - and a good plywood, like Baltic Birch, will work well in this instance, too. The rail is mostly for two things - to make up for the recess of the back, so that the cabinet can sit flush against the wall, and to provide some "beef" so the screw or bolt doesn't pull out through the 1/4" back material. Plywood works for both of those things, and it offers you a cost savings over solid wood. My local supplier here had a 5' x 5' sheet of 1/2" Baltic Birch plywood on sale for $17 last month. You can get a whole lotta hanging rails out of a sheet that big.

Hope this answers your question - I'm still not sure this is what you were asking about! If not, write back and I'll try to help a little more.

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com
My woodworking blog: www.wooditis.blogspot.com