You will need:
- (3) sheets of 20mm plywood or MDF/Supawood (for all parts except P, Q)
- (1) sheet (1.5 x 1.5m) of 3mm plywood or MDF/Supawood (for part P)
- Wood glue
- 5mm finishing nails
- 3mm drywall screws
- (5) pieces 20 x 100mm pine, 1.8m (for desktop, part Q)
- Polyurethane varnish
- Wood filler
- Gloss enamel - white + one colour
- (8) round wood knobs (40mm diameter) with screws, for ball feet
[Download Cutting List PDF]
[Download Assembly Diagram PDF]
Here's how:
Using a portable circular saw or table saw, cut the plywood sheets into parts A through M. (Set aside the extra material for drawer parts N and O.) next, use the table saw with a 20mm dado blade to cut the 6mm-deep rabbets on parts A, B. D, F, and J. For the drawer bank top and bottom panels (K), rabbet the rear edge, then cut three dadoes for the dividers as shown in the illustration opposite. All joinery details are cut on the inside face of each part and only along certain edges.
Assemble the Cube Modules
The 38cm cube modules are the main support structure for this project, so assemble them first. Glue the edge of a bottom panel (B) into the rabbeted lower edge of one side panel (A) as shown, making sure the edges are flush at the front and back. Clamp tightly, then drive finishing nails to secure the joint. Repeat for the other side panel, then attach the top panel to this assembly. Dry-fit the back panel (C) to check the fit, then glue and nail it into the rabbeted rear edges of the cube. Repeat for the second full cube module, then follow a similar sequence to assemble the two half-cube modules and two mini-cubes.
Build Drawers
Cut the drawer sides (N) and backs/fronts (O) from the remaining plywood. Refer to the drawer assembly illustration to make the rabbet joints and groove for the drawer bottom. Designate the drawer fronts and drill a 25mm hole with the spade or Forstner bit in the centre of each to create a finger pull. Sand the rim of each hole to a comfortable contour, or ease the rim edge with a roundover bit and router. Assemble the four drawers using glue and finishing nails. Follow the cube module assembly sequence and techniques.
Glue Up Desktop
Check the 20 x 100mm pine stock to make sure the edges are square and undamaged; trim edges on the table saw if necessary. Glue the five boards together, edge to edge, to make the desktop. (For easier assembly and a stronger panel, consider using a biscuit joiner, router, or dowelling jig to modify the edges for accurate alignment and more gluing surface; simple edge-butt joints will work fine if you don't have these tools.) Start by gluing and clamping the two straightest boards together; leave the ends long for trimming later. Allow the glue to set for an hour or two, then add the other boards, one at a time, again allowing for glue setup. As you add each piece, check to ensure the panel remains flat. Add the last board, then leave the assembly in clamps overnight.
The next day, use a sharp chisel to scrape off the glue that has squeezed out, then sand the joints flush. Cut the laminated top to size using the table saw or portable circular saw. Seal all surfaces with at least two coats of clear varnish.
Finish and Assemble
Use a hammer and nail set to countersink all the finishing nails in the cube modules and drawers, then fill the holes with wood filler. Let dry and sand flush. Apply a coat of latex primer to all surfaces (drawer interiors are optional), then paint the cubes and other modules as desired. Let dry, and recoat as necessary.
To assemble the desk, install the ball knob feet on the two base cubes. Drill four holes in each cube bottom as shown, then attach the knob feet with the screws provided. Drill an identical set of holes through the top panel of each cube, then set the drawer bank on top of the cubes as shown. Fasten with drywall screws driven up through the cube into the drawer bank structure. Install the drawers.
The maple desktop sits on top of the drawer bank, and the half- and mini-cubes rest on the desktop. To prevent shifting, add a few dabs of adhesive or several pieces of thick double-sided tape to the bottom of the desktop and the cubes.
Adjust the height and create a student's desk by repositioning the half-cube modules underneath the drawer bank. Make sure to fasten the modules together with screws if you change the configuration. |
