Step 7: Cut the Handles and Assemble the Tray

this old house editor mark powers cutting the tray handles out of a board
Photo: Wendell T. Webber
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Using a 3/8-inch bit, create an entry hole for the jigsaw blade inside each handle mark. Cut out each handle and ease the edges of the holes with a rasp.

Using a 1 5/8-inch trim head screws and wood glue, glue and screw the 1x4 sides with the handles to the outside edges of the tray bottom. Glue and screw the 23-inch 1x3s onto the outside edges of the tray bottom and 1x4 sides. Install two 10½-inch cleats to the bottom of the tray 1 inch from each end. These will keep the tray from sliding off the box.
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    Tools List

    • flathead screwdriver
      Screwdriver
    • pencil compass
      Pencil Compass
    • rasp
      Rasp
    • jigsaw
      Jigsaw
    • drill
      Drill/driver fitted with a 3/8-inch drill bit
    • combination square
      Combination Square

    Shopping List

    1. 1x12 laminated shelving board Get two 6-foot boards

    2. 1x2 Get one 6-foot board

    3. 1x3 Get one 6-foot board

    4. 1x4 Get at least 2 feet

    5. 2-quart dog dishes with lip edge Get two dishes

    6. 1 5/8-inch #6 trim head screws

    7. Wood glue

    8. Wood filler

    9. Contact paper

    10. Piano hinge Get one that's 18 to 22 inches long

    11. Magnetic door catch

    12. Friction door slide

    13. Door handle

    14. Latex primer

    15. Latex semi-gloss paint