How to Build a Garage Storage System

Walls in the garage or shed can be
converted into valuable storage space with clever construction.

This project shows how to cover existing plasterboard with 3mm plywood for a hard-working, easy-clean surface.

 Back to Storage.

Frame the walls

Using 45mm-wide strips of 19mm plywood, frame the plywood-covered wall. At the corners, nail the strips flat against the adjoining walls, and run strips across the top and bottom.

Cut the rails

Use a circular or tablesaw with a ripping guide to cut 65mm-wide strips of 3mm plywood and 90mm-wide strips of 19mm plywood.

TIP You should get 13 rails from a sheet of 19mm plywood and 18 strips from a sheet of 3mm plywood.

Router the chamfers
Use a router with a chamfer bit
to cut three 45° chamfers, 3mm deep on each 19mm strip.

TIP If you don’t have a router, round
the edges with abrasive paper.

Make the rails

Using adhesive and a pair of 19mm brads every 300mm, secure the 3mm plywood strips to the back of the 19mm strips of plywood, flush with the non-chamfered edge. Apply water-based polyurethane to the front of the 3mm ply.

Make the hanger cleats

Use a circular saw fitted with a metal-cutting blade to cut the 20 x 20mm aluminium angle and 50mm-wide flat stock into 100mm lengths, rounding the edges using a file or abrasive paper.

Drill the cleats

Make three 4mm holes for screws in the angled cleats and two in the flat cleats, 16mm from top edge and sides, then countersink with a 10mm standard drill bit.

TIP Wear eye protection when cutting and drilling aluminium.

Attach the angled cleats

Cut the shelves to size then screw the cleats to each shelf, about 10mm from the ends, using a straightedge to keep them flush and parallel with the back of the shelf.

Add the shelf brackets

Position the shelf brackets using a 19mm plywood spacer block, adding a strip of duct tape to slightly widen the space so the cleats slip onto the rails.

Make the hanger strips

Cut 115 x 115mm plywood mounting plates for small hooks, glue and nail a 40mm-wide plywood hanger strips on the back and coat with polyurethane. Secure flat cleats, about 6mm from the edge of the hanger strip, with 30mm screws.

Attach the hooks

Pre-drill and screw hooks into the mounting plates, near the top where they can penetrate two layers of plywood.

TIP You could make larger mounting plates for bins, drawer units and a bicycle holder.

Materials

Standard dressed-all-round (DAR) sizes of timber vary from state to state.

Add shelves and
mounting plates

Slip the cleats over the rails and push down to anchor the shelves and mounting plates. Use plywood offcuts to customise racks to store tools such as chisels, screwdrivers and clamps.