I needed an EXPEDIT shelf unit that was 3 squares across and 2 rows high. Simple enough, right? Wrong. IKEA doesn’t make this size.
I looked everywhere—apparently, you can find it through specialty retailers in some countries, but I’m in Italy and had zero luck.
So I did what any reasonable person would do: I bought a larger EXPEDIT and cut it down myself.
Sounds crazy? Maybe. But it worked perfectly, and now I have exactly the shelf I needed at a fraction of what custom furniture would cost. Here’s how I did it.
Step-by-Step: How to Create a Custom 3×2 EXPEDIT Shelf
Materials:
- EXPEDIT shelving unit (or the KALLAX shelving unit) – the larger size you will be cutting down
- Timber reinforcement piece (45mm thickness)
- Wood glue
- L-brackets (optional, but recommended for extra stability)
- Screws
Tools:
- Wood saw (a fine-toothed saw works best to avoid chipping)
- Measuring tape
- Pencil for marking
- Drill with 6mm bit
- Clamps to hold pieces while gluing
Step 1: Prepare Your Expedit Components
First things first: lay out all your EXPEDIT components and take a good look at what you’re working with. Yes, it might seem daunting, but trust the process! It’s actually pretty easy, just remember to measure carefully.
Step 2: How to Cut IKEA Expedit Panels (Without Ruining Them)
Take the two long components and measure out exactly 104 cm, and draw a line across with your pencil. Double-check your marks. Then check again.
When you’re ready to cut, use a fine-toothed wood saw and work slowly and deliberately. The EXPEDIT has a white melamine covering that will chip or peel if you rush through this step. Think smooth, steady strokes rather than aggressive sawing.
Pro tip: Put painter’s tape along your cut line before sawing. This helps minimize chipping on the laminate and gives you a cleaner edge.
Step 3: Reinforcing Your Cut Expedit for Maximum Stability
Now that you’ve made your cuts, you need to add structural support where you’ve shortened the panels. Without it, your shelf won’t have the stability it needs.
Cut a piece of timber to 45mm (this matches the internal dimension of the panel) and apply a generous amount of quality wood glue. Position it in the middle of what will be your upper panel. You don’t need to add reinforcement to the bottom panel since it’ll be resting on the floor and bearing less stress.
Use clamps to hold everything firmly in place while the glue dries. Let it cure for at least the time recommended on your glue bottle.
Step 4: Drilling Guide for Modified Expedit Assembly
If you have cut the panel EXACTLY at 104 cm, this step will be easier. The lateral reinforcements that are already inside the panel sections should be perfectly positioned for attaching your side panels.
Time to mark your drilling points. You need to find the center for each screw hole:
- 18mm from the lateral face
- 25mm from the other faces (right in the symmetry plane)
Mark these spots clearly with your pencil, then drill holes with a 6mm diameter bit. Take your time here.
Step 5: Assembling Your Custom-Sized Expedit
Now comes the fun part—assembly! Follow IKEA’s standard assembly instructions, but with your custom-cut pieces. Everything should fit together just like the original design intended, except now it’s the size you need.
Step 6: Adding Extra Support with L-Brackets (Recommended)
For added security, attach L-brackets to connect the lateral panels to your added timber reinforcement. This may be necessary if you’re loading up the shelving unit with heavy books or using it in a high-traffic area.
What Your Finished 3×2 Expedit Should Look Like
What you’ll end up with is a perfectly proportioned 3×2 Expedit shelf that fits your space. It’ll have all the stability and functionality of the original, just in the exact dimensions you actually needed.
I hope this little guide will be useful for someone else!
~ Giorgio Bartolozzi, Prato, Italy
Can You Shorten a KALLAX Shelf?
Here’s the question on everyone’s mind: since IKEA discontinued the EXPEDIT and replaced it with the KALLAX, can you use this same technique?
The short answer is yes! The KALLAX is essentially the EXPEDIT’s successor with nearly identical dimensions and construction. The cube openings are the same size (33cm), and the overall build uses the same honeycomb cardboard core with melamine coating.
However, there are a few things to keep in mind:
The similarities:
- Same basic construction method
- Same cube dimensions (33cm x 33cm)
- Same reinforcement needs after cutting
What might be different:
- The 104cm measurement may not work for the KALLAX. We recommend you measure the KALLAX shelving for the best length to cut.
- KALLAX panels may be slightly thinner in some versions (check your specific model)
- The internal reinforcement structure could vary slightly depending on the size you start with
- Some users report the KALLAX being slightly less sturdy than the original EXPEDIT, so those L-brackets become even more important
How to Adapt This Hack for KALLAX Units
My advice? If you’re working with a KALLAX, follow the same steps but pay extra attention during Step 1 when you’re examining the components. Check where the internal reinforcements are located before you make your cuts. You might need to adjust your measurements by a few millimeters to ensure you’re cutting in a spot where you’ll still have something solid to screw into.
Also, definitely don’t skip the L-brackets with a KALLAX. That little bit of extra stability will make all the difference.
The good news is that the KALLAX line is still in production and readily available, so you can actually go out and try this hack today. The EXPEDIT might be gone, but its hackable spirit lives on!
Here’s a video on how to shorten a KALLAX shelving unit:
Have you tried this hack or created your own IKEA modification? We’d love to hear about your DIY furniture adventures! Send in your hack.