Building a Modern Cat Shed: A Badger Workshop Build

Here is a detailed breakdown of the build, having a closer look at the techniques and materials used by Matt from Badger Workshop.

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With the arrival of autumn, the temperature drops and the rain sets in, making outdoor life a little less comfortable for neighbourhood cats. Matt from Badger Workshop noticed that a local cat named Clyde—brother to a more sensible indoor cat named Bonnie—preferred hanging around the workshop yard rather than staying inside.

To give Clyde a reprieve from the British weather, Matt decided to construct a custom, modern cat shelter. Utilizing reclaimed materials and precise joinery, he built a structure that looks more like a piece of architectural furniture than a standard pet house. Here is a step-by-step look at how he did it.

1. Material Preparation and Panel Glue-Up

Matt started by raiding his scrap pile, pulling out 2×3 timber left over from a previous Halloween display. Rather than using thin plywood for the main structure, he opted for solid timber to provide better thermal mass and insulation against the cold.

• Lamination: He glued the 2x3s together to create five distinct “five-board panels.”
• Milling: Once the glue cured, Matt ran the rough panels through a thicknesser. This cleaned up the glue lines and ensured every panel was perfectly flat and uniform in thickness, essential for the joinery to follow.

2. The 45-Degree Structure

To keep the geometry simple yet effective, Matt designed the entire structure around 45-degree angles.

Using a track saw with a rail guide, he cut bevels on the edges of the wall and roof panels. The pitch of the roof was formed by simply joining two panels at a 45-degree miter.

• Assembly: Matt applied wood glue to the mitered edges and clamped them tight.
• Reinforcement: To ensure longevity, he drove screws into the joints. He made sure to countersink the screws deeply, allowing him to fill the holes later for a smooth, invisible finish.

3. Creating Recessed Front and Back Panels

Instead of simply screwing plywood sheets onto the face of the frame, Matt decided to inset them for a cleaner, higher-end look.

• Routing a Rebate: He used a handheld router equipped with a rebate (rabbet) bit to carve a shallow recess along the inner edge of the front and back of the house frame.
• Chiselling the Corners: Because a spinning router bit leaves rounded corners, Matt used a sharp chisel to square off the corners of the recess. This ensured the plywood panels would slot in perfectly without gaps.
• Templating: To get the exact shape for the plywood, Matt placed the assembled carcass directly onto the plywood sheet and traced the outline. He then cut the panels out using a jigsaw.

4. The Entrance and Interior Finish

For the entryway, Matt avoided complex measurements. He placed a metal dog bowl onto the front plywood panel, traced the arc, and cut out the doorway with a jigsaw.

Before sealing up the box, he addressed the interior aesthetics:

• Interior Stain: He applied a coat of Treatex Dark Oak hard wax oil to the inside walls. This gave the interior a cozy, “log cabin” vibe while offering some protection to the wood.
• Back Panel Installation: Once the interior was dry, the back plywood panel was set into the routed recess and tacked in place with nails.

5. Exterior Finishing and Hardware

With the structure complete, Matt focused on weatherproofing and aesthetics.

• Filling and Sanding: He used wood filler to cover the countersunk screw holes and any imperfections in the timber. Once dry, the entire unit was sanded down to a smooth finish.
• Painting: To match the existing Badger Workshop exterior, Matt painted the shelter with Rainbow Barn Paint in black. This paint is durable, water-resistant, and flexible enough to handle outdoor temperature changes.
• The Feet: To prevent the wood from absorbing moisture from the ground—a common cause of rot in outdoor wooden structures—Matt attached four small metal hairpin legs to the base. This elevated the shelter, keeping it dry and adding a modern industrial touch.

The Result

The final product is a sleek, black, architectural shelter that fits perfectly in the alleyway next to the workshop. It offers Clyde a warm, dry vantage point to watch the world go by.

While Clyde has currently discovered the comforts of human beds indoors, the Badger Workshop shelter stands ready for whenever he needs a bit of solitude or protection from an autumn shower.

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