Build cutlery box yourself - construction manual

Build cutlery box yourself - construction manual: yourself

There are cutlery boxes in many shapes, colors and sizes. But rarely they are stable enough to be transported regularly or fit exactly in the designated cabinet.

With our construction manual you can build your own cutlery box according to your ideas. You can use our given dimensions or adapt them with our tips to your requirements. The self-made cutlery box is Stable enough to be taken out of the closet if necessary and to be placed at the barbecue area or on the table.

Beautify your barbecue area with a self-made unique and banish the monotonous plastic bowls.

Required tools and work materials

Tools and tools

  • Scriber (pencil, steel measure, angle)
  • Table saw (alternatively jigsaw)
  • Table saw for grooving (alternatively router or milling table)
  • Bench drill or cordless screwdriver
  • Orbital sander or delta sander
  • clamps

Required work materials

  • 2 x multiplex 460 x 80 x 12 mm
  • 5 x multiplex 270 x 80 x 12 mm
  • 5 x pressboard 276 x 106 x 3 mm
  • 30 x screws 3.2 x 40 mm

Step 1 - Cutting the multiplex panels

The cutlery tray has the outer dimensions of 460 x 270 x 80 mm, which corresponds to the interior dimensions of many kitchen cabinets and also offers space for larger steak knives. Of course, the dimensions can also be individually designed and adapted to their own cabinets. The calculation of the new dimensions is quite simple.

Build cutlery box yourself - construction manual: build

Cutting takes place on the table saw

The front and back can be adapted to the available space in the cabinet. Please note, however, that the cabinet door or concealed hinges may influence the clear width in the cabinet and have to be removed. Should the cutlery box later find space in a drawer, there should be enough space for removal in the compartment.

To determine the depth of the cutlery box, the depth of the cupboard or drawer can also be taken over. Again, the possibility of removal is observed. When calculating the partition wall length 2 times the thickness of the used multiplex plate has to be deducted.

Build cutlery box yourself - construction manual: construction

Control sample shows possible errors in the cut

The shelves from pressboard should be kept in the groove with 3 mm each. For this, each insert must therefore be 6 mm wider and 6 mm longer. The size is calculated as follows:

  • Length = dividing wall length + 6 mm
  • Width = 5 times the board thickness from the length of the front and back and divide the result by the number of compartments planned. This results in the clear width of the individual subjects. Then add 6 mm for the slot guide to maintain the width of the shelves.

The cutting takes place optimally on a table saw with stop, so that all items receive a uniform measure. For this, first cut the front, back and side panels. If slight deviations occur in the lengths, the shelves can then be easily adapted. For this purpose it makes sense to cut the floors only in the third step - after grooving the multiplex boards.

Step 2 - Grooves of the side parts

For grooving the boards is ideally suited to the table saw. If you have a milling table, Of course you can use it as well. A router is due to the near-edge processing only partially suitable.

Build cutlery box yourself - construction manual: build

Grooves with the table saw

If the table saw is used for grooving, the saw blade guard and the riving knife must be dismounted. Please observe the safety instructions. Then the saw blade is lowered so that it protrudes just over 3 mm above the table. Since it is difficult to measure the setting, test cuts in a residual material are helpful. Should the shelves later be able to accommodate about 3 mm in the side boards, the groove should be about 3.2 mm deep. The more precise the work here, the more accurate will be the later construction, as the cutlery box automatically aligns itself at right angles. Since all parts are grooved in this form, the adjustment of the stop can be done relatively freely. However, keep a minimum distance of 5 mm to prevent breakout of the groove.

Build cutlery box yourself - construction manual: cutlery

Slice three sides on both sides

The front and back obtained, as two side parts each have a groove. However, three of the five side panels must be grooved from both sides as they each accommodate two pressboard panels.

If all parts are grooved, it is makes sense to recheck the clear width and only then to saw the shelves. If deviations occur, they can now be compensated. Here it helps to set up the side parts including the shelves and to check the total length. If necessary, the lengths of the front and back can now be adjusted.

Build cutlery box yourself - construction manual: yourself

Check the width in the test setup

security Alert

If the saw blade guard and splitting wedge are dismantled on a table saw, it no longer complies with the safety regulations and may only be used for grooving. For further cuts, the splitting wedge must be reassembled. If this is missing, it can the cut board at the back end of the saw blade contract and jam with it. In this case, as the saw blade moves from the bottom to the top, the board is dragged and in the worst case thrown against the operator. Never saw without splitting wedge!

Step 3 - Drilling the screw holes

Build cutlery box yourself - construction manual: yourself

Drilling on the bench drill

When composing, you have the choice whether they want to screw or glue the self-made cutlery box. If this is often used when grilling in the summer or outdoor kitchen, the screw variant is clearly in the advantage. If required, all individual parts can be disassembled, cleaned or even sanded down. Naturally glued and oiled well, the self-made cutlery box can of course also be wiped damp.

When screwing we recommend the mentioned very thin screws to use with extra small head. These can be screwed flush without countersinking and have a drill bit that prevents the wood from bursting. The tear takes place according to the positions of the partitions and should be carried out very accurately to give a good screw pattern later. The drill bit size may only be minimally smaller than the screw diameter. This ensures a sufficiently large hole in which the screw can rotate later, but still provides the screw head enough support.

Step 4 - Sand and oil

Build cutlery box yourself - construction manual: construction

Grind with 240 grit

For a smooth surface need all surfaces are sanded. Prior to oiling, however, a maximum of 240 grit should be used to ensure that the wood is still able to absorb oil. If the glue variant is preferred, the cutlery box must first be glued and then oiled.

Build cutlery box yourself - construction manual: cutlery

Oil in two passes

Once all surfaces have been sanded and the grooves deburred, the first oil application can be carried out. The oil used should be odorless and tasteless and applied in at least two steps. For this, coat all sides thoroughly with oil and absorb excess oil after about 10 minutes with a soft cloth. Dry puddles or drops on the wood, they form sticky stains that are difficult to remove and cause unsightly discoloration.

After a drying time of 12 to 24 hours (Please note processing instructions), another order can be made. Uncontracted oil must be resumed and the surface polished. Caution: oily rags can self-ignite. Please always keep them in metal containers or throw them into a bucket filled with water.

Step 5 - Assembly and bolting

Build cutlery box yourself - construction manual: cutlery

Fix with screw clamps and screw together

The screwing should be done very carefully, so that all screw heads pull evenly into the wood and do not stick out or cause deep holes. It is therefore necessary to dispense with the use of the torque limiting of the cordless screwdriver. Especially the very narrow screw heads affect the applied torque so minimal that the torque limiter can hardly work exactly.

After successful assembly you can look forward to your first own cutlery box, The ideal way to fit exactly into existing cabinets and can also be customized.

We wish have fun with the next barbecue pleasure.

Build cutlery box yourself - construction manual: cutlery

Build cutlery box yourself - construction manual: yourself

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