Expedit

Published on September 18th, 2012 | by Jules Yap

11

How to: Cut an Expedit down to 3X2





Materials: Expedit

Description: I needed an Expedit with 2 rows of 3 squares, but unfortunately it doesn’t exist! I read somewhere that it is possible to find it from different shops, but none of them is available in Italy, from where I am writing! So I decided to try to create it.

Step 1: Look at the component and don’t get discouraged!!

Step 2: take the two long components and cut them EXACTLY at 104 cm. I used directly a wood saw, but you need to pay much attention, otherwise the white covering will be ruined.

Step 3: I added a timber to reinforce the structure. In particular I put it in the middle of the upper panel. I don’t think it is necessary to add it also to the panel that is going to rest on the floor. The timber must have one dimension of 45 mm. Use a good glue for wood and keep the thin faces of the panel pressed

Step 4: If you have cut the panel EXACTLY at 104 cm, the lateral reinforcements visible in the panel section are long enough to screw the lateral panel on them. Therefore, mark them to find the centre for the hole: 18 mm from the lateral face and 25 mm (i.e. in the symmetry plane) from the other faces. Then drill the holes with a diameter of 6 mm.

Step 5: Assembly everything as Ikea suggests.

If you want, you can also screw an L-bracket that links the lateral panel to the added reinforcement (just in case..), but for the use I am going to do, it is not necessary!

I hope this little guide will be useful for someone else!
Goodbye hackers!!

~ Giorgio Bartolozzi, Prato, Italy

 

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The Author

Jules Yap

"I am Jules, the engine behind IKEAHackers and the one who keeps this site up and running. My mission is to capture all the wonderful, inspiring, clever hacks and ideas for our much loved IKEA items".

11 Responses to How to: Cut an Expedit down to 3X2

  1. Joseph says:

    Glad I found your article. I needed to convert an Ikea Kallax 4 x 2 to 3 x 2. Using a dental pick in the dowel holes I had sussed out that the long pieces were some kind of hollow core with a solid frame all around. But I was still a bit queasy about cutting into it until I saw your pictures of exactly how it was constructed.

    I shortened the pieces on my table saw using a 40 tooth carbide combination blade. I did a couple of experimental test cuts on the end to be cut off, using blue painter’s tape to lessen potential tearout of the veneer. I also have a zero clearance insert on my table saw. Result was a perfect single pass cut with zero tearout for the final cuts.

    I used one of the long shelves mounted with dowels inserted to mark exactly where the cut should be. I then set the fence to do both offcuts to make sure they were both exactly the same length.

    To drill the end holes, instead of measuring and marking, I cut a 1-1/2″ strip off the end of one of the offcuts. I used this as a jig to drill the holes by clamping it against the piece and drilling through the factory holes. This gives you perfect alignment of the new holes. The 1-1/2″ block also keeps the bit true. One other thing, I think a 6mm bit is too large. I ended up using a #3 size bit. It was a snug fit in the existing holes – I couldn’t get the 6mm bit to slip in.

    The cut off end still seems pretty solid, so I didn’t go through the trouble of gluing in an insert.

    The assemble modified Kallax went together and looks perfect.

  2. Jenny says:

    Has anyone tried this since the range changed to Kallax. I also need to reduce a unit but wonder if the structure inside the panels is difference since they changed the units?

  3. Andrew says:

    I d
    I’d this to make a 2×1 from a 2×2. It worked a treat. I didn’t bother to reinforce at step 3 because it was going short side down. I used a circular power saw because you get a good perpendicular cut that way. Going slowly it didn’t rip the surface too badly.

  4. Ais says:

    Looks fab! What is the width of the final product ?

  5. Kris says:

    Well done, I think I’m going to need a saw table. I never get these things straight with a hand saw !

  6. Cécile says:

    great how-to !
    many thanks, because I actually needed a 2×3 combination ! :)

  7. leo says:

    good job, Giorgio!

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