"One"-Hour "Box" Turned Into A Two-Hour Shelf
My garage work area is getting very cluttered and could benefit from a cabinet to store tools and supplies in. Since the carcass of the cabinet would basically be a box, I thought I would also try to make just the box portion in an hour as part of the one-hour box challenge. After an hour, I barely had the frame of the box/cabinet ready and was in the middle of cutting the back. After two hours, I had something that could pass as a shelf )or a cabinet with no door). But while I failed the challenge, I now have a place to stash some of the mess on my work table, learned a bunch, and had some fun. That makes it a success!

The finished shelf with some tools in it

I started off with a 10-foot 1x8, 8-foot 1x2, a piece of peg board and a piece of lauan plywood for the back. I ended up not using the peg board and the 1x2 because I didn't make a door.

This 300mm ryoba is great. First step is to cut the 1x8 into three pieces: side+top, side+bottom, and rest.

Side+top and side+bottom cut. The middle shelf will come out of the third piece, but since I was planning to just make the box part, I set it aside.

I clamped the two long pieces together and measured out the top and bottom parts. With the two pieces clamped together, I could cut both the top and the bottom at the same time.

Top and bottom cut. It took more than 1 minute, as the clock would suggest, but I accidentally stopped the timer before making the cut. It's probably closer to 20min at this point.

Used my ol' #5 to clean up the end grain.

Grooves done. I needed a 3/16" blade on my plow plane but it had a 1/4" blade in it when I brought it out so I lost some time finding the blade and switching it..

Pocket holes done. I had another mishap here: my drill battery ran out after drilling the first hole so I had to go dig up a fresh battery. I haven't seen many pocket hole boxes as part of the challenge. Maybe it's not challenging enough.

Partially assembled. Only two screws on either side for now. This was supposed to let me size the backing board.

At the one hour mark (actually, more like 1:05 with my timer failure), I was still in the processes of cutting out the plywood back. I wasn't going to make the challenge, but I kept going.

I cleaned up the edges a bit with my little Harbor Freight plane. It's not bad for using on plywood.

This is when the real disaster struck: my measurements or marking was about 1/2" off.

I assembled everything anyway and assembled it. What's not easy to see is that the sides are a bit too short also.

I forged ahead with the middle shelf. I had transferred the length of either the top or the bottom piece before assembly so I didn't have to make a new measurement.

I was going to make the middle shelf shallower at first. The back would be one piece and the middle shelf would extend to the back, but not through it. However, since the back is too short, I decided to groove both sides of the middle shelf, cut the back into two pieces. and install one piece above and one piece below the middle shelf.

More pocket holes. I've been trying to stay away from pocket holes so that I could learn other joinery techniques. The problem was that it was taking a long time to perfect dovetails and dadoes so all of the projects I wanted or needed to do (like this one) were piling up. Recently, I realized that I could do both: pocket hole quick shop projects and spend more time on the projects that go into the house.

Shelf in place, The paper towel role and glass cleaner bottle are my spacers for the bottom shelf.

Here we are with the back panel cut in two. The last step is assembly which ended at about 2 hours total into the project.