Fabricating Two-Inch-Thick Hollow Shelves for a Built-In
How are the 2" thick hollow panels typically made up for this type of design? I would prefer to use plywood instead of MDF if possible for weight reasons.
From the original questioner:
Thanks. I'm talking about carcass and shelves. How about 1/4" veneer ply skinned over a hardwood frame/lattice?
From contributor P:
I just finished a home office with 2" thick shelves on all the uppers. Here's how I built my adjustable shelves: 2 pieces of 3/4 ply with a solid 3/4 x 2" edge (maple in my case). Pocket screw one piece of ply to the solid edge. Glue and brad nail 1"W x 1/2" spacers along front and back edge. Glue and clamp second piece of 3/4 ply to spacers and solid edge. Flush trim the solid edging. Kind of like a poor man's torsion box, but way quicker to make, and probably just as strong. Bonus is that when viewed from the side, you can see through it, giving you a 1/2" channel for running wires.
Carcass was a different story. One big face frame, 3 boxes pocket screwed where possible to face frame. Where not possible to pocket, I glued, clamped and attached cabinet sides to adjacent sides using trim head screws hidden in shelf pin holes. No lights in this one, but I've done them on other ones.
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