Created 2008-08-20 15:21:24 by Eric Stromer

Prepare the project by cleaning out the pantry and removing all the shelving. Take all measurements of the pantry to figure out the best use of space, and to determine the amount of wood needed for the project. The materials list includes measurements based on a sample pantry with a width of 19 1/2". Adjust dimensions based on the size of your pantry. Using plywood, (Cut list A) build a rollout base for the pantry. This base is needed to accommodate heavy-duty drawer glides for the unit. Attach all pieces with wood glue and 1 3/4" finish nails.

Next, build the rollout platform. (Cut list B) This rollout platform will fit inside the rollout base. Sand down all your panels and channels (Cut list C) and assemble the pantry box, using wood glue and 1 3/4" finish nails. The middle piece of the box sits 7" in from the side between the 2nd and 3rd dado channels. (*Note: You should have 1" of space between the middle board and the dado channels on either side.)

Sand down all the wood you will need for the face frame (Cut list D). Make pocket holes (using a pocket hole jig and drill), and put the face frames together. Clamp the faces together and use wood glue and screws to assemble the frames. Attach the face frame to the pantry box, using wood glue and a brad nailer. The sides of the face frame should be flush with the pantry box opening. The top and bottom of the face frame should overlap the pantry box opening by 3/4". (Use a 3/4" scrap piece of wood to get the right overlap measurement for both top and bottom.) Attach the finish back piece of 3/4" plywood. (This last piece of finish 3/4" plywood will also help you line up your face frame correctly in the back)

Attach the bottom of the base (that you built in Step 4) into the inside of the pantry with 1 1/4" cabinet screws. Next you'll want to attach the rollout platform to the rollout base (which you built in Step 4) with the drawer glides. The drawer glides sit flush against the sides and back of the rollout base. The rollout platform is attached to the drawer glide and sits 1/4" above the bottom of the base.

Attach the pantry box to the top of the sliding platform with screws. If you have a spice rack to place in front (See GMC Trade Secret on building a spice rack) then the pantry box sits 3 3/4" back from the front of the roll-out platform to allow room for the spice rack. If you do not have a spice rack then place the pantry box flush with the front of the roll-out platform. If you choose to make a spice rack, attach your spice rack to the front of the pantry box with 1 1/4" screws. In preparation for attaching the spice rack, attach a 2" strip of 3/4" plywood the length of the pantry box on the front of the pantry box and touching the face frames where you will screw in your spice rack. If you choose not to build a spice rack, then place a solid 3/4" panel of oak on the front of the pantry box. If you would like to create a more uniform look, use a solid piece of veneer to make trim. Possible uses for this trim might be the top, the back, or to hide drawer glides. Enjoy your new rollout pantry!

Cut list:
A) Roll-out base: 3/4" plywood: 2 sides @ 23" x 3 1/2", 1 back @ 20" x 3 1/2", Bottom piece is made of 1/4" plywood: 1 @ 23" x 21 1/2" B) Roll-out platform: 3/4" plywood: 2 sides @ 22" x 3 1/2", 2 front and back pieces @ 17" x 3 1/2", 1 top @ 22" x 18 1/2" C) Pantry box: 3/4" plywood: 2 front and back pieces @ 44" x 18 1/2", 2 top and bottom pieces @ 18 1/2" x 17 1/2", 1 middle piece @ 44" x 16". Cut a dado channel on each of the front and back pieces for the shelf strips. For each piece measure in 1 5/16", 5 11/16", 9 1/16", and 17 3/16" for the dado channel cut. These measurements are for the center of the dado channel. (Depending on your shelf strips, dado channels are normally cut at 5/8" wide by 3/8" deep) D) Face Frames: 3/4" solid oak: 4 sides @ 48 5/8" x 1 1/2", 2 top pieces @ 16" x 4", 2 bottom pieces @ 16" x 2 3/8" (*Note: Only the top and bottom pieces get pocket holes on the ends. Also, be sure that the top and bottom pieces sit inside of the sidepieces so that the face frame is the correct width.) Cut a finish back piece of 3/4" plywood @ 18 1/2" x 48 5/8"

What You'll Need:
2-4'x 8' Oak plywood 3/4"
1-2'x 2' Oak plywood 1/4"
2-1"x 8"x6' Solid Oak
1 3/4" finished nails, 1 1/4" wood screws, 1 pair of 20" Extra heavy duty-500+ pound rating drawer glides, 4- 8' shelf strips, shelf clips, clear polyurethane, wood glue.
Table saw
Chop saw
Electric sander
Nail gun
Screw gun
Tape measure
Pocket hole jig
Safety glasses
Ear plugs