ᐅ Why don’t the drill holes always line up properly during the Malm assembly?

Hello everyone, I am currently assembling the Malm shelf from Ikea and have encountered a recurring issue: why don’t the drilled holes always align as described in the instructions? Specifically, I mean that the holes on the side panels and the shelves sometimes don’t line up perfectly, making assembly difficult or even impossible. I have checked several times to make sure I’m not assembling it incorrectly, but it almost seems like the holes on some parts are slightly offset—almost as if there are manufacturing tolerances. Has anyone experienced this or can explain why this might happen? Are there any solutions to work around this issue without damaging the furniture?

The issue often corresponds to manufacturing tolerances. Sometimes the holes are slightly misaligned, which can happen in large-scale production. It is best to make minor adjustments using a drill.

In some Malm sets, the material thickness or chamfer may not be completely precise. Check whether you are using the correct parts that fit together properly. Drilling an additional hole often helps if something doesn’t fit.

gojan7 schrieb:
The issue often corresponds to manufacturing tolerances.

Thank you, that sounds plausible. However, I’m surprised that this happens quite frequently with a large manufacturer like Ikea. Does anyone know the typical range of such tolerances? I would have expected standard furniture to fit with millimeter precision.

Tobias schrieb:
With some Malm sets, the material thickness or chamfer isn’t always exactly right.

That could indeed be a factor, especially when combining different production batches.

I have assembled the Malm shelf many times and noticed that the fit can actually vary between different production batches. Although the drill holes are placed precisely according to the specifications, slight deviations of 0.5 mm (0.02 inches) are quite common.

In practice, this means that if wood-based materials fluctuate slightly during manufacturing—due to moisture, for example—the dimensions can also change slightly. This can affect the fit.

I recommend carefully adjusting with a sharp drill during assembly, without applying too much pressure. Small adjustments with sandpaper or a chisel can also be made gently. This preserves the stability without damaging the appearance.

It's great that some facts are already coming together here! 🙂 I had exactly the same problem – the holes on my Malm didn’t line up properly. In the end, I simply applied some sanding oil to the drill holes with a small brush, which made it easier to screw in the screws. It worked really well, and the shelf is rock solid! With a bit of patience, you’ll manage it too, don’t give up! 👍