PB&J Pullout Shelf...Part 1

After five attempts of the pullout shelf and it's snuggie..think I've got it. With five dogs over 100 pounds each, and one closer to 200, had to make sure this shelf would be durable. Wouldn't do to have a tail wag and it fall apart. I did test this, and it didn't break with 150 lbs on it! Didn't want to go crazy and add more weight, but there wasn't even a creak! Since we have a pool, our house tends to be party central, I'm not going to encourage my guests to sit here, but if some drunkie sits on it, I'm not going to have a baby over it either. As with the PB&J version, it can be pulled out by a leftie, (me) or a righty, (the rest of the world), which means the shelf runs the width of the inner frame on the lounge chair. Now that I've got it down pat, everything I build, I'll be looking to tuck a pullout shelf in it! *** If a toddler sits on it, my main concern, totally safe, we tested it several times :)
   Bear with me, I'm snap happy, I'll admit it, and will include pics as I go. This system is designed for scrap or less than perfect wood. Don't throw away that knotty pine, here's a place for it. If your wood doesn't look so pretty, but it's straight, perfect.
  I've included measurements, I double checked, it will work with the Ana plan, http://ana-white.com/2010/04/when-we-were-installing-plumbing-and.html Outdoor Chaise Lounge, or any Lounge really, just need to measure the width and subtract an inch. Let's get to the plan!

Chicken or the Egg> which comes first? For me, I've built my shelf first, and built the Snuggie around it, that was the easiest for my brain...But you can always build the Snuggie, measure the inside, then build your shelf.

15 1/4 x23 1/2

So here goes the Shelf...basic run of the mill shelf, could've been straighter on the slats, Used my Kreg to put it together, this is the dry fit. Sanded and Stained everything prior to tightening too hard to get everything waterproofed once it's all together, and these will be used by a pool.

A different look for my second chair...didn't have enough 1x3's left over, so busted out the 1x4 scraps...same measurements. Same concept..kregged together, shelf sides 23 1/2 long, oh, and the inner slats are 9 1/4 long. The spacing is a matter of preference, so get creative. Mix and match wood, find the look you like.

Moving on...to the SNUGGIE!! (My daughter named it, "looks like a snuggie!")  As I'm working, I may have pics of either shelf, since I'm building 2 shelves at once, one shelf is unfinished, to cut down on the confusion...just realized this as I'm looking through the pics. I really wanted strength, function, and durability, so I tested this plan a few times, and this way rocked. No shelf wobble, nice and flat, ie> no drink spills :)
Snuggie measurements: 17 x22 1/2..you can find your measurements on a completed chair by measuring from one inner side stringer to the other..it needs to sit on top of the stringers, not in between, very important. You're shelf is going to be 1 inch longer than the Snuggie, this is for low profile, all together, the Snuggie and the shelf are 2 inches thick using 1x3 boards. Once completed, only the shelf 3/4 inch, is really visible from the side.
 Make sure to check for square before and after every step, EXTREMELY IMPORTANT, so you're shelf will open and close with ease.

I work on the ground, it makes it easier for me. I stand on my boards as I'm kregging them, to avoid any movement. Rough side will be down when complete.

     You've made a flat square, now add  inner supports.. These are important so there is strength to your shelf no matter which side you pull from

Checking the fit on the shelf. There will be an overhang on each side of your shelf, don't worry, as pictured, 1x2's will go in that space. 

the shelf is sitting on scrap 1x3's. Snuggled in 1x2's to form a U around shelf. Glue applied to 1x2s, lay the base support you made smooth side down on top of the 1x2's and upside down shelf.  check for square and attach using nail gun, or screws (predrill first so 1x2's don't split. You need 1/4 inch for the shelf to slide, I used a scrap piece of wood between shelf and 1x2. 

it will help keep the 1x2 in place while you're securing it, if you butt a scrap piece of wood up against it.

3 different views of the base with slides attached. 

here's the Snuggie on it's side, with 1x2's attached...and because I'm crazy, I felt the need to add screws as well..

Here's your shelf, snuggie, and measuring a 1x3 for upper slide.

Dry Fit your shelf into the Snuggie, make sure you can slide with ease either way. 

far side, upper slide is attached to the 1x2 via the nailer. 

Upper slide almost lays on top of shelf, but isn't touching it. This is a guide to keep your shelf from tipping forward when pulled out. Basically keeps your shelf nice and straight.

this is what the finished project looks like. The upper slides, with the stamp on them, will be used to screw to the lounger. I find that it's easier to attach to the stringer while you're building, if you're following Ana's plan, attach after Step 2, turn the Stringers upside down and attach using screws to the stringers, BEFORE you apply the 1x4 sides. Not impossible to add after the build, just heavy trying to flip the lounger over to add this. 

While your shelf is out, flip it upside down and screw a 1 1/2 screw halfway in. this is your stop, so the shelf doesn't come completely out. There will be a part 2 with attachment and the screw pic to explain better.

I hope this is understandable, If there is anything that's unclear, just ask.  It's 3:30 am, (can't sleep, work nightshift), and am a very new blogger, I'm hoping I didn't forget anything.  Hope this is useful for someone, I was so happy to be able to have that PB&J shelf!!