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Homeowners plan to build a pullout for pots and pans beneath their kitchen cook top. The pullout will make maximum use of this storage area and eliminate the need to get down on the floor and move items at the front of the current storage to access whatever is at the back. They have designed a pullout unit with two wide slide-out trays that will fit into the available space, retaining the existing cabinet doors but removing a shelf and a supporting stile from the cabinet frame. Construction materials include poplar lumber and birch plywood.

Determine the Dimensions.
Plan the pullout dimensions and design to use available space and address any issues such as electrical wiring or gas piping that you must avoid. Assemble your tools and safety equipment. The homeowners use computer-aided drawing software to design the pullout.

Reinforce the Opening, if Necessary
Reinforce the upper edge of the opening by installing a strip of solid one-by-two cut to length. Clamp the strip inside the upper edge of the cabinet and secure it by driving screws through the strip into the cabinet base. This hidden support will prevent any sagging when you remove the stile from the center of the opening. Use a jigsaw to remove the stile because it will block installation and operation of the wide trays in the pullout assembly.

Remove Cabinet Doors.
Use a power driver to remove the screws that attach the doors to the base cabinet and set the doors aside until you reinstall them after the pullout is constructed and installed.

Step Title
Cut the existing shelves into convenient sections with a jigsaw and break them away from the walls. Remove them along with any nails that protrude from the interior cabinet walls.

Purchase Plywood and Solid Lumber
Purchase poplar lumber and sheets of birch plywood from your home improvement store.

Cut Plywood Panels for the Case
Use a table saw to cut the plywood into panels of the appropriate dimension for the pullout case the open fronted box that will hold the trays. You will need a bottom, a top, two ends, and a back.

Apply Glue to Panel Edges
Apply glue to the top edge of the two plywood end panels. Brush the glue with a small paintbrush to distribute it evenly.

Set Top Panel in Place
Set the top panel on the end panels.

Use Corner Clamps to Secure Panels
Slip on corner clamps to hold the joints in position.

Set Bottom Panel in Position
Apply glue to the bottom edge of the plywood end panels, distributing it with the paintbrush, and then set the bottom panel in place. Use corner clamps again to hold them together temporarily.

Clamp Joints
Brace all the joints with adjustable clamps.

Nail Joints
Use a pneumatic nail gun to drive nails to secure the joints permanently. Turn the open box so that the back edges are upwards.

Set Back Panel in Place
Add glue to the back edges of the top, bottom, and two side panels and then set the back panel in place.

Attach Back
Attach the back with the nail gun. Flip the box so that the open side is upward.

Apply Edging to Front of Case
Apply glue to the raw edges at the front of the pullout case, after you cut narrow finishing strips from the solid poplar. Set the strips in the glue, allowing any excess length to overhang at the corners you will trim the overhang in a later step.

Nail Edging Strips
Use a pneumatic brad gun/pin nailer to secure the strips to the edge of the case.

Trim Edging Strips
Trim any overhang on the finishing strips using a Japanese hand saw.

Sand
Sand the faced edge lightly with a sanding block to remove any burrs or splinters.

Cut of Drawer Parts
Prepare to build the drawers/trays by cutting the bottom panels from 1/2-inch plywood to provide additional rigidity. Cut two sides, a front, and a back for each tray from the poplar. The back will be a few inches taller to stop pans from slipping off the rear of the pullout. For each tray, you will mount the sides and a back on top of the bottom panel. However, you will mount the front flush to the tray?s forward face, allowing it to overhang about an inch on the sides to conceal the drawer glides.

Glue Bottom to Drawer Sides
Set the bottom panel on top of the side panels, after setting them on edge and applying glue to the upper edge. At this point, the tray is upside down.

Install Drawer Glides
Secure the sides to the trays bottom panel permanently, driving in nails with the nail gun while leaving room for reinforcing screws added in the next steps.

Drill Pilot Holes in Bottom
Pre-drill countersunk holes through the bottom panel into the side panels to receive reinforcing screws.

Install Reinforcing Screws in Bottom
Drive the reinforcing screws through the bottom and into the sides using a power drill/driver. By lapping the bottom on top of the sides and attaching them with countersunk screws, you have a neat joint that will not interfere with the operation of the drawer glides. Flip the assembly so that it is right side upward for the next step.

Set Drawer Back in Position
Slide the back component into place between the side components, after applying glue where it will join the sides and bottom. Flip it upside down for the next step.

Secure Drawer Back
Secure the back with the nail gun and then drive screws through the tray bottom and into the back panel to reinforce the joint. Pre-drill and countersink holes for the screws as you did to reinforce the side panels.

Install Front Drawer Panel
Glue and nail the front panel flush with the front face of the tray and centered on its width. Remember that you cut the front panel wider than the basic tray, so the front panel will overhang the sides of the tray and cover the glide mechanisms.

Install Drawer Glides in Case
Position and install the stationary half of four full extension drawer glides on the inside walls of the pullout case?two on each side. For the lower tray, lift each glide component off the bottom of the cabinet by placing a temporary strip of half-inch plywood underneath while you position and secure the glides with screws. Repeat this process without the plywood strip for the stationary portion of the glides for the upper tray. Measure carefully to position the glides accurately and allow room for both trays to operate properly when you assemble the pullout.

Install Drawer Glides on Pull-Outs
Install the moving part of each glide assembly on the sides of the lower and upper trays. You will have one component on each side of the trays.

Fit Drawers to Case
Test the glides by setting the tray in place, engaging the portion of the glide on the side with the receiving component on the side of the pullout case. Remove the trays again until the pullout case is in position in the kitchen to avoid carrying the additional weight. You may want to paint the entire assembly, too.

Install Case
Set the pullout case in the cavity beneath the cook top and gently push it into place. Put the trays into position, glide to glide.

Reinstall Cabinet Doors
Reinstall the cabinet doors, using a power driver to replace the screws through the hinges into the cabinet base.