Pegboard System.pdf
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PEGBOARD
SYSTEM
© 2009 August Home Publishing Co.
F
eature
P
roject
P
egboard
S
yStem
Here’s a tool rack that takes a different approach to using common
pegboard. You can customize it to fit your needs and your tools.
O
ne item common to almost all
workshops is a sheet or two
of pegboard and an assort-
ment of wire hooks that hold the
usual items — screwdrivers, pliers,
hammers, and other hand tools.
Falling Hangers.
One thing that has
always bothered me about pegboard
storage is that almost every time I
reach for a tool, the hook comes off
with it or falls to the floor.
To avoid this, I came up with a
whole new system of tool racks and
storage units that stay put on peg-
board. The system uses common
L-hooks, which are available at any
hardware store or home center.
These hooks are screwed to the
back of each storage unit. (For more
on this, see the box on page 4.)
Wasted space.
Another thing that
bothers me about traditional peg-
board systems is how they waste
space. They don’t seem to hold as
many tools as they should.
So when I designed this new
system, I modified some common
tool and clamp racks to make them
more efficient. And I added adjust-
able shelves and drawers.
cUstOMiZe.
Though this system has
a lot of interesting features, the best
part is how easily it can be custom-
ized to fit your needs. You can add
more shelves or drawers if you need
them. And with the L-hooks, it’s
easy to move things around to make
them more convenient.
Materials.
This entire pegboard
system is built with common materials
found at most lumberyards or home
centers. To build the frame, I used
one six-foot 2x8 and a little less than a
full sheet (4x8) of
1
⁄
4
" pegboard.
For all of the shelves, drawers,
and different storage units, I simply
used pine boards,
3
⁄
4
" plywood, and
some small pieces of
1
⁄
4
" hardboard.
1
www.Woodsmith.com
© 2009 August Home Publishing Co. All Rights Reser ved.
Construction Details
Overall Dimensions:
36" x 72" x 6"
TOP
A
RIB
C
!/4" PEGBOARD
D
SANDPAPER FILE
SANDPAPER
DISPENSER
SIDE
B
SHELF
CHISEL &
SCREWDRIVER
RACKS
DRAWER UNIT
(4 DRAWER)
DRAWER UNIT
(2 DRAWER)
1 -LONG
L-HOOK
#/4"
Materials & HarDWare
PEGBOARD FRAME
A
S
Top/Bottom(2)
#/4x4!/4-6
•(16)#8x1#/4"FhWoodscrews
•%/32"-dia.x1#/4"-longL-hooks*
•#4x#/8"FhWoodscrews*
•#6x1"FhWoodscrews*
•#8x1!/2"FhWoodscrews*
•1"wirebrads*
•Drawerpullswithlabelholders*
•1"x1"butthingesw/screws*
•Hacksawblade*
•Toiletpaperholder*
*Quantitieswilldependonindividualneeds
1!/2
x1!/2-71
Top/Bottom(2)
T
!/4hdbd.-4x5!/2
CHISEL & SCREWDRIVER RACKS
U
Back(1)
1!/2
x1!/2-36
B
Sides(2)
1!/2
x1!/4-34
C
Ribs(2)
ChiselRack(1)
#/4x2!/4-12
D
Pegboard(1)
!/4pgbd.-35x71
V
ScrewdriverRack(1)
#/4x2!/4-18
DRAWER UNIT
E
SANDPAPER FILE
W Front(1)
FrameTop/Bottom(2)
#/4x6-24
#/4x6!/2-12#/4
F
FrameSides(2)
#/4x6-4!/4
X
Back(1)
#/4x8-12#/4
Y
Sides(2)
#/4x5!/4-8
G
FrameBack(1)
!/4hdbd.-4x23
Z
Bottom(1)
!/4hdbd.-4%/8x11#/4
H
DrawerSides*
!/2x3&/16-5!/2
AA Dividers*
!/4hdbd.-9#/4x11
I
Lg.DrawerFront/Back(4)
!/2x3&/16-11#/16
CLAMP RACKS
BB Top(1)
J
Sm.DrawerFront/Back(10)
!/2x3&/16-4&/16
#/4ply.-4x12
1
⁄
2
K
Lg.DrawerBottom(2) !/4hdbd.-5!/4x10!!/16
#/4ply.-3
1
⁄
4
x12
1
⁄
2
CC Back(1)
L
Sm.DrawerBottom(5)
!/4hdbd.-3!%/16x5!/4
#/4ply.-3
1
⁄
4
x3
1
⁄
4
DDSupports(2)
M
Lg.DrawerDivider(4)
!/4hdbd.-2!%/16x5!/4
C-CLAMP RACK
EE Back(1)
N
Sm.DrawerDivider(5) !/4hdbd.-2!%/16x3!%/16
SHELF
O
#/4x5-11
1
1
⁄
2
-2
1
⁄
4
x5
FF
Top(1)
Shelf(1)
#/4x6-24
3
⁄
4
-dia.x4
1
⁄
4
GG Dowels(4)
P
Back(1)
#/4x3!/4-23
PULL SAW & SQUARE HOLDERS
HH Shelf(1)
SANDPAPER DISPENSER
Q
#/4x3!/2-8
Sides(2)
!/2x3#/4-4!/4
#/4x1
1
⁄
4
-7
II
Back(1)
R
Door(1)
!/2x5-6
2
www.Woodsmith.com
© 2009 August Home Publishing Co. All Rights Reser ved.
1
Pegboard Frame
SIDE
The frame that the pegboard hangs
on is made from standard “two-
by” lumber (1
1
⁄
2
" thick). I used
1
⁄
4
"
pegboard instead of
1
⁄
8
" pegboard
because it will hold the heavy weight
of the bins and shelves better.
FraMe.
Start by cutting the top/
bottom and sides to a width of 1
1
⁄
2
"
and to finished lengths (Figure 1).
Then you can cut the two rein-
forcing ribs to finished width and
rough length. Also, rip them to fin-
ished thickness (1
1
⁄
4
").
rabbet.
To join the frame, first cut
a rabbet on the inside edges of the
top, bottom, and sides to hold the
1
⁄
4
"
pegboard. To do this, I used a dado
blade buried in an auxiliary fence on
the table saw (Figure 2).
nOtcH.
To join the sides to the top
and bottom, cut a notch on both ends
of each side (Figure 3). Cut these
notches just wide enough to accept
the top and bottom pieces.
dadO.
After the sides are notched,
the next step is to cut two dadoes in
the top and bottom to hold the ribs,
like you see in Figure 5.
asseMbly.
With the dadoes cut, the
frame is ready to be assembled. To
do this, first drill and screw the sides
to the top and bottom (Figure 4).
1
!/2"
x 1
!/2"
x 36"
B
A
TOP
1
!/2"
x 1
!/2"
x 71"
RIB
1
!/2"
x 1
!/4"
x 34"
C
BOTTOM
22#/4
1
!/2"
x 1
!/2"
x 71"
A
1!/2
22!/2
1!/2
22#/4
PEGBOARD
x 35" x 71"
!/4"
D
PEGBOARD FRAME
Then cut the ribs to finished length
and screw them in place (Figure 5).
pegbOard.
Once the frame is
screwed together, cut the pegboard
to fit between the rabbets. Cut the
pegboard so the holes are about
1
⁄
2
"
from the edge (Figure 6). That way
the L-hooks in the storage units won’t
contact the sides or ribs. And the units
won’t hang over the edge of the frame.
It also means you can use the holes in
the pegboard as screw holes.
cHaMFer.
Finally, rout an
1
⁄
8
" chamfer
around the outside edge (Figure 7).
2
3
4
!/4
B
A
AUXILIARY
FENCE
1
CUT RABBET ON
INSIDE FACE
5
6
7
!/2
!/2
ROUT
CHAMFER ALONG
FRONT EDGES
OF FRAME ASSEMBLY
!/8"
#12 x 1" Fh
WOODSCREW
CHAMFER
BIT
No. ???
Woodsmith
4
3
www.Woodsmith.com
© 2009 August Home Publishing Co. All Rights Reser ved.
8
Drawer Unit
To help organize some of the hard-
ware scattered throughout the shop,
I decided to build five-drawer and
two-drawer storage units.
The frames for both drawer units
are identical. The only differences
are the size and number of drawers.
FraMe.
A frame consists of the top
and bottom, two sides, and a back.
Each is
3
⁄
4
" pine, except for the
1
⁄
4
"
hardboard back (Figure 8).
To hold the back, a rabbet runs
along the back edge of each piece
(Figure 8a). Rabbets are also cut on
either side of the top and bottom to
hold the sides (Figure 8b).
Now glue and screw the top and
bottom to the sides. Then cut the
back to size and glue it in place.
Next, chamfer the top and
bottom. Then screw three L-hooks
into the back edge of the top. The
box below shows how to install them
so the unit hangs properly.
draWers.
The frames are ready for
the drawers. I used
1
⁄
2
"-thick stock for
all the parts, except the
1
⁄
4
" hardboard
bottoms and dividers (Figure 9).
When building either size drawer,
the basic approach is the same.
There are only two dif ferences
— the lengths of the fronts and the
backs, and the number of dividers.
To begin, cut the sides and
fronts/backs to size (Figure 9).
Now cut a rabbet on the front and
back pieces for the sides. Then cut
a groove on the inside face of each
piece for the bottom.
Next, cut
1
⁄
4
"-deep dadoes for
the dividers. On the larger drawers,
the dadoes are cut in the fronts and
the backs. On the smaller drawers,
they’re cut in the sides.
Now dry assemble each drawer to
determine the size of the bottom and
dividers (or divider). After they’re
cut to size, glue and nail the drawers
together. Finally, I added a pull with a
slot for a label card to each drawer.
a.
b.
#/4
!/4
!/2
BACK
!/4
#/8
TOP/
BOTTOM
DRAWER
FRAME
#/8
SIDE
9
SHOP-TIP: L-HOOK SYSTEM
All of the storage units and
shelves for this pegboard
system hang the same way.
They’re perfect for this
project because, unlike typ-
ical metal pegboard hooks,
it’s almost impossible for
them to fall out.
To use this system, first
screw 1
3
⁄
4
"-long L-hooks to
the back of each storage
unit (drawing below left).
Then, to hang the unit, tilt
it in the pegboard at a 45°
angle (top photo at right).
As the unit is lowered,
the weight of the unit pulls
the hook tight against
the back of the pegboard
(bottom photo at right).
!/8" CHAMFER
ALLOWS UNIT
TO BE
INSTALLED
ON PEGBOARD
!/4
#/8
%/32"
-DIA. x 1 -LONG
L-HOOK
#/4"
No. ???
Woodsmith
5
4
www.Woodsmith.com
©
2009 August Home Publishing Co. All Rights Reser ved.
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aramita
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