Offcut-first small organizer

Small Shop Plans · v1 · 240 × 150 × 55 mm · measured thickness 6 mm

Feasible cutting layout — every part is accounted for. Kerf 3 mm; edge trim 5 mm on each used sheet side. Cutting maps create rectangular blanks; complete any operations in the machining schedule before assembly. Display units: millimeters. Do not measure from the illustration.

Your project checklist

Make a two-lane packet organizer from usable remnants, adding matching sheet stock only when parts remain unplaced.

Measure

Measure each remnant after excluding damaged or unsquare edges.
Measure filled sample packets with labels and closures included.

Tools and access

A saw and guide for straight cuts
A square, measuring rule and caliper
Clamps suitable for the dry assembly
A sanding block for accessible edges

Using the organizer

Enter each usable remnant with its actual thickness and quantity.
Compare the offcut-first result with the standard-sheet result and keep a complete layout.
Store packets by label and remove one packet before opening it.

Check your result

Every required part is assigned to stock of matching measured thickness.
The stock report identifies any backup sheet actually used.
The largest sample packet lifts from its lane without being squeezed.

If the fit is wrong

If a remnant has a defect, reduce its usable rectangular size and recalculate.
If parts remain unplaced, add matching stock or reduce the design before exporting the full bundle.

Dimensions and parts

Interior: 228 × 138 × 49 mm. Clear compartment width: 111.00 mm. Total base clearance: 0 mm per axis.

Cut length	Cut width	Thickness	Qty	Grain
240 mm	55 mm	6 mm	2	Along length
138 mm	55 mm	6 mm	2	Along length
228 mm	138 mm	6 mm	1	Unrestricted
138 mm	49 mm	6 mm	1	Along length

Materials

Uses 0 standard sheet(s) and 2 existing offcut(s). Check your inventory before buying.
S1: 2 of 2 used · 300 × 200 × 6 mm plywood (existing offcut).
S2: 0 of 1 used · 400 × 300 × 6 mm plywood (standard sheet). Unused stock stays whole.
Four self-adhesive felt pads.
Adhesive suitable for the selected sheet. Prepare according to the adhesive label and actual contact faces; no universal quantity or cure time.
Compatible finish and abrasive. Choose for the actual material and intended indoor use.

Connections and machining

Fixed dividers · 6 pieces · 6 mm plywood. Fixed dividers stand on the inset base and meet the front and back walls. Glue the divider bottoms and ends after the outer shell is square.

No grooves or notches are required. Cut the rectangular parts, then follow the connection details.

Assembly

1. Measure and mark
Measure the actual sheet thickness (6 mm in this plan). Mark front / back F, left / right L, base P and dividers D. Recalculate if the measured thickness differs. Measure each offcut and keep only pieces with sound, square edges.
Parts: F, L, P, D · Start here
2. Cut and label the parts
Follow the numbered full-width cuts in the cutting sequence, then subdivide each labeled child region. Keep the part IDs and grain arrows. Use the instructions supplied with your tools; this plan is not tool training.
Parts: F, L, P, D · After measure
3. Dry-fit the outer walls
Front and back span 240 mm. Fit the 138 mm side walls between them. Check the outside footprint 240 × 150 mm and square the corners. The inset base is 228 × 138 mm; its underside sits flush with the wall bottoms. Total base clearance is 0 mm per axis (0 mm on each side).
Parts: F, L, P · After cut
4. Assemble the base and walls
Prepare and bond the butt-joint contact faces using an adhesive suitable for your sheet. Center the inset base at z = 0 mm. Check squareness before clamping. For a clearance gap, verify the adhesive allows that gap; use zero clearance or revise the fit if it does not.
Parts: F, L, P · After dry-fit
5. Position the dividers
Mark each divider from the inside face of the left wall. Place the first divider after 111.00 mm of clear space; repeat at a pitch of 117.00 mm. Glue the bottom edge onto P and both ends against F. Each compartment has 111.00 × 138 mm clear floor space. These are straight glued partitions, with no grooves or hidden fasteners.
Parts: D, F, P · After glue
6. Cure, finish and check the fit
Follow the adhesive manufacturer's cure and handling instructions. Smooth edges and apply a finish compatible with your materials. Attach four self-adhesive felt pads under the base corners. The cutting plan tries offcuts first. Add a matching standard sheet if any parts remain unplaced. Use for light desktop items; no load rating is provided.
Parts: F, L, P, D · After divide

Sheet S1.1

Follow cuts in numbered order. Coordinates refer to the original sheet origin (top left). Trim all four edges first. Every cut spans its listed parent region. Part IDs match the parts list.

Cut	Parent region	Direction	Coordinate (mm)	First child	Second child
C1	N1	horizontal	60	N4	N5
C2	N4	vertical	245	N6	N7
C3	N5	horizontal	118	N8	N9
C4	N8	vertical	245	N10	N11
C5	N9	horizontal	176	N16	N17
C6	N16	vertical	143	N18	N19
C7	N19	vertical	284	N20	N21

Sheet S1.2

Follow cuts in numbered order. Coordinates refer to the original sheet origin (top left). Trim all four edges first. Every cut spans its listed parent region. Part IDs match the parts list.

Cut	Parent region	Direction	Coordinate (mm)	First child	Second child
C1	N2	horizontal	143	N12	N13
C2	N12	vertical	233	N14	N15
C3	N13	vertical	143	N22	N23

Sheet S2.1 · unused stock

Keep this stock whole. No cutting or edge trim is needed.

Cut	Parent region	Direction	Coordinate (mm)	First child	Second child

Remaining stock

Parts 0.0798 m²; trim 0.0098 m²; kerf 0.0047 m²; all offcuts 0.1457 m². Stock utilization 33.25% (parts / all listed stock area).

S2.1: 400 × 300 mm — unused, keep whole.
S1.1: 47 × 55 mm at (248, 5).
S1.1: 47 × 55 mm at (248, 63).
S1.2: 59 × 138 mm at (236, 5).
S1.2: 149 × 49 mm at (146, 146).