Folding Metal Pegboard Tool Wall
Introduction: Folding Metal Pegboard Tool Wall
I highly recommend downloading my free plans that also include all dimensions. The plans are designed to complement the steps here and also provide additional diagrams. Use the two together to get the best results.
Tools Used
* Table Saw
* Drill
* Kreg Pockethole Jig
* Angle Grinder with Cut-Off Wheel (or hacksaw)
* Fine Hand File
* Clamps
* Tape Measure
* Miter Saw (optional)
* Impact Driver (optional)
* <PERSON> (optional)
Supplies
* Wall Control Panel(s)
* 2x4s
* 3/4" Plywood
* Piano Hinge
* Pockethole Screws
* Hinge Screws
* CA Glue
* CA Glue Accelerant (optional)
* Wood Glue
* 1" Dowel
* Hardwood Scrap
Step 1: Mill 2x4 Square
Most dimensions will be based on the Wall Control panel. Keep it close by to reference measurements during the build. The steps are for one panel, so be sure to repeat each step for each panel you want to hang.
Most 2x4s from a big box store are rough and have some warping to them. We'll start by milling the 2x4 square.
The hinge mechanism will be on the short edge of the Wall Control panel. Cut the 2x4 a little longer than the short edge of the panel.
Set your table saw fence to 3 1/4" and rip off one rounded edge. Adjust to 3" and rip the other side square.
We still need to clean up the faces. I set my table saw to 1 3/8" and ripped the face off in two passes. I then adjusted the fence to 1 1/4" and ripped the final face of the 2x4 off, again in two passes. If you are not comfortable making this cut, take some extra time and sand each side smooth. If you have a thickness planer, plane each face till the total thickness is 1 1/4".
Step 2: Cut Notch in 2x4
Set your milled 2x4 on the back of the Wall Control panel and mark out a notch to cut out. The offcut will be slotted behind back panel mounting piece for stability.
Once marked, take the piece over to your table saw and set your fence based on your marks. 431
Make sure to adjust the saw blade height as well. We'll want to keep the offcut.
If you do not feel comfortable making this cut, you can hog out all the material, but then cut a small piece from another 2x4 piece to fill the void.
Once the notch is cut, cut all pieces to their final length based on the panel.
Step 3: Install 2x4 Cleat to Panel
Slide to the small offcut behind the panel's back lip. It should be snug, but pop in easily. You may need to cut the offcut slightly shorter for it to fit.
Clamp the other side of the 2x4 so it is flush with the front and the notch fits over the back lip of the panel and offcut. Use some clamps to keep everything in place and flip the assembly over.
Drill a pilot hole through the front top mounting holes of the panel and both 2x4 pieces. Drive a screw through both pieces.
Flip the panel assembly over and drill several pilot holes through the back and drive screws to fully secure the 2x4 back together.
Step 4: Install Panel Cross Pieces
To add some extra strength to the panels, we need to add a crosspiece to the middle and bottom of the panel. These will be located in the same places the panel would normally be secured to a wall.
Start by marking both sides of the pieces for holes. Pre-drill to prevent the edges from cracking, then secure to the back of the panel.
I did this step at the end after the panel was already hung and highly recommend adding these while still on the bench. It will be much easier to secure the pieces before it is above a workbench.
Step 5: Cut Plywood to Size
Time to build the opposite side of the hinge. Because we'll be loading the panel with accessories and tools, we'll need to offset the panel from the ceiling. Measure how far from the panel your largest accessory will be. This will be the offset height. We won't factor in the thickness of the Top Mount to provide some additional buffer.
For each panel, cut to pieces of 3/4" plywood to the height measured above. Then, cut each piece to the width of the Wall Control panel.
While you are cutting plywood, cut a Top Mount for each panel. 56