Home Improvement | 14 December 2016How to Build a Door-Backed Kitchen Island Share article facebook twitter google pinterest One man’s trash is another man’s treasure. Building with Secondhand Stuff shows you how to create gorgeous projects for your home from reclaimed materials, like this rustic door-backed kitchen island. CUTTING LIST TOOLS AND MATERIALS Power drill Sawhorses (2) Bar clamps Orbital sander and sand paper Painter’s tape Paintbrush Eye and ear protection Work gloves 1 quart chalkboard paint 1 quart white latex primer 1 quart bright white paint ¼ pound 2″ wood screws (12) 21/3″ wood screws (12) 4″ wood screws Prep the door by removing door handles and locks, hinges, and any other hardware. Rip the door down as necessary to suit your desired dimensions (the island design can also be changed to accommodate the door size). Sand the door smooth and prime it. Alternative: Use a hole saw to cut a plug from a piece of scrap wood to fill the doorknob hole in the door. Glue the plug in the hole and sand smooth. Note: If the hole will be hidden behind the counter, or if you’re reclaiming an old pocket door, you won’t need to fill the hole. Paint the door white, except for the recessed panels. When the paint has completely dried, tape around the panels with painter’s tape, and paint the panels with chalkboard paint, following the paint manufacturer’s instructions. Cut the front apron 25″ long, and two side aprons 17″ long. Cut the legs from reclaimed timbers, 34½” long. Most circular saws will not cut through a 4 x 4 in one cut. Mark the timber all the way around and cut one side, rotate 90°, and cut following the new line. Repeat until you’ve cut through the leg. Cut the skirts from reclaimed lumber to the same lengths as the aprons, and cut 2 x 2 cleats for the skirts and aprons. Sand all the framing pieces to prep for painting, as necessary. Note: If the reclaimed pieces have interesting surface appearances, you can opt to leave them natural. Cut seven 2 x 4s, 32″ long. Line the boards up parallel on a flat work surface with the most attractive faces down, and butted edge to edge to create the island’s counter. Clamp the boards together with bar clamps. Position two 2 x 4 braces, 20″ long, 10″ in from each end. Center the braces side to side and ensure they are perpendicular to the boards. Drill pilot holes and screw the braces to the underside of each board with two 2″ wood screws. Drill pilot holes and screw the cleats flush along the edges of the aprons and skirts using 2″ wood screws for the aprons and 2½” wood screws for the skirts. Measure and mark 10″ up from the bottom of each leg and screw the skirts to the legs using 3″ wood screws driven through the cleats, with the skirt bottom edges aligned with the marks. Screw the aprons to the legs in the same way to create the sides. Lay the two leg assemblies on their front edges, parallel to each other. Screw the front apron and front skirt in place between the two sets of legs, with the apron and skirt face down on the work surface. Lay the base frame face down on the door, with the bottoms of the legs flush with the bottom of the door. Mark the top of the legs on each side; this is the position for attaching the door to the back legs. Align the tops of the back legs with the marks on the door. Drill pilot holes down through the cleats and into the door every 4″. Drive 4″ wood screws through the holes. Stand the assembly upright. Screw 2 x 2 nailers across the inside faces of the front and back legs, flush with the top edges of the legs. Screw identical nailers in the same position lower on the legs, flush with the top of the skirts. Cut the 1 x 12 reclaimed fence planks for the bottom shelf 32″ long and rip down the shelves as necessary to combine them into the 24 x 32″ lower shelf. Measure and mark for the notches in the front plank, to fit around the front legs. Use a jigsaw to cut the notches. Screw the planks in place by drilling pilot holes up through the nailers into the planks, and then driving 2″ wood screws up through the holes. Optional: If you want to make the island mobile, screw 3″ casters to the bottoms of the legs and the door bottoms. Make sure at least one caster is a locking unit. Optional: For a distressed finish, scatter sharp rocks over the island counter top and put a scrap piece of plywood over the rocks. Walk on the plywood to scar the wood. Finish the top with an antique finish (right) or, if you’ll be preparing food on top, use a food-safe finish, such as boiled linseed oil. Place the top in position and screw it in place by driving 3″ wood screws up through the nailers. Buy from an Online Retailer US: UK: A practical manual packed with useful information and tips on how to convert salvaged wood, reclaimed materials, and even some types of shop waste into usable materials for building. From Craig’s List, your basement, and estate sales, you can salvage what you need to upcycle all kinds of cool things. You can build tables, install hardwood floors and reclaimed windows, mason stone walls, and much more using free or very inexpensive, high-quality, recycled materials. You’ll encounter opportunities to upcycle usable building materials everywhere. If you exercise good judgment and know a few salvage tricks, you can take advantage of these chances to gather free (or nearly free) project supplies and put them to work in your house. Building with Secondhand Stuff, 2nd edition takes green remodeling and construction practices to new heights. From deconstruction methods and salvaging tips to plotting efficient cutting plans and devising creative new uses for everyday items, it is packed with clever ways to obtain low-cost materials (and reduce landfill). From plywood to hardwood flooring, to windows, doors, carpeting and more, salvaging building materials can save you thousands of dollars (and is about as green as you can get). This book is a hands-on, do-it-yourselfer’s guide that shows you how to identify materials that can be salvaged efficiently and then gives you step-by-step instructions on how to go about doing it. This second edition of the best-selling book includes new projects such as a pallet chair, pallet table, chalkboard message door, door headboard, and a reclaimed window greenhouse. Share article facebook twitter google pinterest If you have any comments on this article please contact us or get in touch via social media.