Expert: Jamie Yocono - 12/14/2006

Question
Hi-  I teach kindergarten and am looking to build some free standing counter
top units with shelves underneath  They closed on the three sides, and
open at the front for stools and shelves).  The tops are going to be six feet by
two feet, and they will be thirty two inches off the ground.  I am planing to
build them exclusively out of plywood.  The problem is that I am planning to
build quite a few of them.  I will need about twelve sheets of plywood.  Being
a kindergarten teacher I am not wealthy.  My initial plan was to buy 3/4 inch
poplar ply from Home Depot.  It is about 33 dollars a sheet.  However, I do
not have a table saw, so I would have to have the cuts made at a Home Depot.  
The last time I did that they were inaccurate to the point of me having to have
a friend rip them down for me.  It was a huge head ache, and I simply don't
have the time to do that again.  I am willing to spend a little extra money if it
means I can have a lumber yard do the cuts.  I have found a lumber yard
which sells fir plywood (I forget the exact grade but one face is good and the
other rougher) for 42 a sheet and birch for 56.  Ideally I would build them all
out of birch but that is just out of my price range.  I am planning to
polyurethane over the wood (no staining for times sake) to protect the
counter tops from the children's destructive powers.  What would look better,
the poplar or the fir?  Is it worth risking cuts at home depot for the price and
the ascetics?  Which one would look better polyurethaned?  Also, I am
planning to use wood glue and screws.  Would it be better for me to rent a
nail gun for the project?  And what are the chances these things will hold up
for years to come?  Thanks for your help,

Answer
Hi Anthony,

Sorry for this long answer! Grad a cup of coffee and put your feet up.  :)

I read your question last night and decided to sleep on it, as I wanted to really think it out. The project you're considering taking on is a big one. And while I'll answer your specific questions, I'd like to point you in a different direction, as well.

First- the quality of materials, as well as the quality of cuts, at any home improvement store leave a lot to be desired. For the most part, those stores cater to the average homeowner. Yes, their prices can be somewhat competitive, but their lumber and plywood are often substandard. Plus- they don't give you a lot of choice.

So right off the top of my head, I would steer you away from purchasing your material from them. More on that later.

Next- if you look at the dimensions of your individual tops, you're wasting a lot of wood. You're only going to get 2 tops out of a 4 x 8 sheet of plywood, and you'll be left with a 2 x 4 foot piece of plywood as waste. I'm not sure if you intend on using that leftover piece to make the lower shelf, but even so, it's not long enough.

Let me address your specific questions, and then I'll offer an opinion.

What would look better, the poplar or the fir?   The Poplar would probably look better than Fir, as it is a hardwood. It is more stable, and less prone to weeping sap that you often see. Plus, generally, Poplar plywood is often better sanded and would provide a better surface for finishing.

Is it worth risking cuts at home depot for the price and the ascetics?   No, not really. Their tools only provide rough cuts, and are often out of square. Considering how much you'll have to do to correct the damage they'll do to the wood, it's not worth it.

Which one would look better polyurethaned? Poplar would look better? Once again, Poplar. It's a hardwood, which is superior for taking a finish.

Also, I am planning to use wood glue and screws.   Would it be better for me to rent a
nail gun for the project? NO, NO, NO. These tables/counters need to last, and they won't if they're nailed together. You'll want to use screws, as nails will work themselves out of the wood over time. Screws and glue are the way to go.

And what are the chances these things will hold up for years to come? If built solidly from the start, they will last a long time. That means using the correct fasteners (screws) and adhesive (probably Titebond glue) and materials. I don't get the impression that these counters are going to be used as actual work surfaces, but rather- as counters for storage, with shelves underneath. So they're no going to get that side to side racking movement that happens with pieces that aren't well constructed. If it's possible, you might want to bolt these to the back wall. This will provide a great deal on rigidity, and will probably make them last longer. You don't need to bolt it every 16", but rather- probably 2 bolts per unit, one on each end.

Here are my thoughts. Use a plywood distributor in your area, and have the school order the material for you. Even if you're paying for it, you'll get a better deal on wood. If you write back to me and tell me your location, I'll try to help with a plywood company in your area. Next- what you want to consider is a "shop grade" plywood. The more plies, the better, as this adds strength. Look for a plywood that doesn't have voids, like a Baltic Birch. My plywood distributor here in Las Vegas has a very nice shop grade plywood for about $30 a sheet. I use it all the time for shelving, workbenches, etc.

Consider using a melamine panel. Melamine is like a plastic covering. It's similar to what most people call "Formica". My old plywood company used to sell melamine panels in about 20 colors, and would often have some GIANT sales on leftover pieces. There were times I would buy these for $3 a sheet. Yes, three dollars. Now- melamine panels in your area might only be available with a particle board core. That's not as bad as you think. New particle board cores (called substrates) are far better than that junk most people think of. In fact, it's called MDF (medium density fiberboard) and it's strong and water resistant.  

Look at it this way- of you use the melamine panels, you don't have to varnish anything. It will save a lot in time and money.

Think modular. Try to work it out that your design uses every bit of the panel goods. They make melamine sheets in 10 foot long panels, and possibly even 6 foot wide pieces. Something like that would give you a huge amount of yield, and NO WASTE. So I suggest going back to the drawing board and try to figure out a way to build them with no waste.

If I were making this project, I would build a lower frame out of 2 x 4's, screwing and gluing them together. These would include a lower stretcher area, where a shelf could be slid into place. I would take all these bases, bolt them to a wall in a few places, and then slide the shelf in place, and lay the top on top, add a few screws, and you're done. No finishing, not too hard, either.

My last suggestion- look to your school district to help out. Are there any woodshop classes? Is there a shop teacher you can ask to help you out? I used to teach college adult ed classes, and we used the woodshop at the local high school. I can't tell you how many times people would wander in with a repair, or a project. We always helped out. A woodshop class could "adopt" your project, and make all those cuts for you on the panel goods. Heck, they might even build the pieces for you. It's worth a shot.

If there isn't a high school woodshop, look for woodworking hobbyists in the area, like retirees. Or woodworking clubs in your area. I'll tell you- you'll never meet a better bunch of people, often willing to take on projects like for the heck of it. Last- call your local college and see if they offer any adult ed classes. Any of these venues might offer you a great deal of help.

Write back with your location, if you want me to try and help out with a plywood company in your area. Good luck, I hope this helps. Please feel free to write back if you have any further questions after reading this. And if this answer was helpful... please take a minute and rate my service. Thanks!

Jamie Yocono
Wood It Is! Custom Cabinetry
Las Vegas, NV
www.wooditis.com