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Fabricating Two-Inch-Thick Hollow Shelves for a Built-In
Question
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. Forum Responses
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.  Click here for higher quality, full size image Would you like to add information to this article? Interested in writing or submitting an article? Have a question about this article? Have you reviewed the related Knowledge Base areas below? 
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