If you have kids, you probably have lots of toys too. So more storage is always helpful, and the Pottery Barn Cameron Storage Unit is a great design with lots of flexibility in configuration. This series of DIY plans are inspired by the Pottery Barn Cameron Storage Unit, and this article focuses on building the base cabinet.

The base cabinet in this design measures 16″ high, by 21″ deep, by 29 1/2″ wide. The plans provide the instructions around building one base unit, but we recommend figuring out how many base units you are going to need and build them all in one assembly line style process.

Materials Required

• 4′ x 8′ x 1/2″ plywood
• 30″ x 3″ x 1/2″ solid wood

Tools Required

• Saw – table or circular
  • Dado blades for your table saw are useful
  • Or a router with a 1/2″ straight bit.
• Nail gun and nails
• Tape measure
• Square
• Wood glue
• Sandpaper
• Wood putty or edge banding

Step 1: Make all of the plywood cuts

Since we want to make more than one of these base units (I personally am making three) we want them to all be exactly the same. The easiest way to do this is to make all of your cuts on similar pieces all at once. This will also save you time with adjusting your tools when switching to different cuts.

These are simple boxes, but we are doing a two-piece top to add some dimension to the design. That means we’ll be cutting six plywood pieces for each box based on the below dimensions:

• Bottom: 29″ x 20 1/2″
• 2 Sides: 20 3/4″ x 15″
• Back: 29″ x 15″
• Lower Top: 29 1/2 x 20 3/4″
• Upper Top: 29 1/2 x 21″

Remember, if you want to build a complete system like you see in the Pottery Barn Cameron Storage Unit, you’ll want to make three of each of the pieces listed above.

Step 2: Cut the toe kick to length

Ones you have all of the plywood pieces cut to size, now is a good time to cut the toe kick. This is the only piece made from solid wood – but even it could just as easily be made from plywood. Simply cut a 1/2″ thick by 3″ wide board down to 29 1/2″.

Remember, if you are using lumber from a big box store what they advertise as 3″ may actually only be 2 1/2″. But you need a full three inches.

Step 3: Cut the rabbets and dadoes in the sides, back, and toe kick

This is probably the most difficult part in building the base unit in this replica of the Pottery Barn Cameron Storage Unit. The cutting of the dadoes and rabbets.

You can either use a dado blade on your table saw, or a 1/2″ straight bit on your router. Either way will work just fine, and there are other methods for accomplishing this task but I won’t go into those here. Personally, I prefer to use the dado stack because I can better control the thickness to exactly match that of the plywood which leads to tighter joints.

Starting with the toe kick, cut out 1/2″ wide by 1/4″ deep rabbet around both sides and the top. So only the bottom will not have an inset edge.

Next, cut a 1/2″ wide by 1/4″ deep dado in the back edge of both side pieces.

Then cut the 1/2″ wide by 1/4″ deep dado on each side piece 2 1/2″ up from the bottom. Cut a similar dado in the inside of the back piece. These dadoes will allow the bottom shelf to be supported on three sides while the toe kick supports the front.

Step 4: Assemble

Now that you have all of the pieces cut and ready, let’s go ahead and get these base units assembled!

Start by attaching the sides, bottom, and back. Use wood glue in the dadoes and rabbets. I’d also highly recommend using corner clamping blocks to ensure you are getting perfect 90 degree corners.

TIP: Now is a great time to paint or stain the inside of the base unit (including the bottom of the lower top. Once you put the top on, it will be much more difficult to paint in the corners. You could paint everything before starting assembly, but then you have to worry about paint getting in the rabbets and dadoes; so I prefer to start painting now.

Once the sides and back are secured, put on the lower top piece. Make certain the edges align on all of the pieces. If they don’t, it means you have something out of square. Use wood glue along the top edges of the sides and back, and then use finish nails down through the top (these will be hidden by the second top piece).

Now glue down the second top piece, ensuring the back edge and side edges are aligned. There should be a 1/4″ overhang on the front to create a shadow line.

Lastly, glue the toe kick in place. You can also use brad nails to hold this piece in place temporarily if you like.

Step 5: Sand and finish

Once all of the pieces are assembled and the glue is dry, go over the entire piece with 180 grit sandpaper to ensure a nice smooth finish. Use wood putty on all of the exposed edges of plywood. Optionally, you can use the edge banding instead if you plan on staining the piece. Since I’m painting mine, I’m just using wood putty and then paying a little extra attention while sanding the edges of the plywood.

Then finally, apply a few coats of your paint or stain of choice and coat with a finish such as polyurethane or wax.

That’s all it takes to build this base unit which was inspired by the Pottery Barn Cameron Storage Unit. Check out the other articles in this series to learn how to build the different variations for the top units.

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