|
|
| Read and Recline / Shelf System and Corner Desk |
From "DIY to the Rescue" episode DTTR-301F |
|
|
Opera singer and minister Liz, and her engineer husband, George and complete bibliophiles. Both have large amounts of books and use their home office as a guest bedroom and library. The two need a solution to get the clutter under control and make their office a place cozy enough for guests.The DIY to the Rescue crew will help the couple build new shelving and install a corner desk; install a Murphy bed; create new closet storage and add paint and finishing touches.

 A wide-view of the triple-duty room.
| 
 Surrounded by bookshelves, the guest bed was neither relaxing nor attractive to guests.
| 
 The desk is cluttered and difficult for two people to share.
|
 |

 A CAD drawing of the corner desk and shelf plan.
|
|
Mitered Edge Shelving System and Corner DeskHost Amy Devers helps George get started on building a corner desk and attractive new bookshelves. Materials: (For six shelves with four vertical supports.) 3/4 birch plywood 10 of 1 x 2 Table saw Tape measure Framing square Screw gun and drill bits Screws Plunge router with straight edge bit and round over bit Nail gun with finish nails Wood glue Fine-grit sandpaper Orbital sander with grit sandpaper Water based wood stain Wood putty that matches stain Small putty knife Rags Rubber gloves Eye protection Stud Finder Level Painters tape Stud finder Countersink drill bit Telescoping pole Metal shelf pegs
 |

 Figure A
|
|  |

 Figure B
|
|  |

 Figure C
|
|  |

 Figure D
|
|  |

 Figure E
|
|
Cutting shelving:- Measure your corner and establish length of shelving.
- Rip birch plywood shelves with a circular saw to manageable length (figure A).
- Use table saw to cut shelving 11" deep and to your specific length (figure B).
- Cut front edge of shelves at an angle for a mitered edge -- set the blade on the table saw to 45 degrees.
- Set the fence for the saw at the right depth for the shelf -- in this case, 11 inches.
- Because the teeth of the table saw rotate downward, place the wood with the good side up for a smooth cut. Work slow and steady. When making long cuts, a little help is often necessary to steady the wood as the cut is completed.
- Using the plywood left over from the shelf, cut a 2" strip of plywood for the front edge.
- To cut the edge, set the blade back to 90 degree and the fence to 2 inches.
- With the 45-degree side against the fence, cut the edge piece as you did the shelf (figure C).
- Use a combination square or a speed square to mark the length of your shelf.
- Cut angles on each shelf by cutting across each end at 45-degree angle on the table saw. At the same time, undercut at a 45-degree angle for the miter for the lip. Adjust the angle of the blade on the table saw to 45 degrees.
- Next, mark the distance between the saw blade and end of the bed. Align a scrap piece of wood along these marks to act as a fence for the saw (figure D).
- Use bar clamps to attach the fence pieces to the wood. With the saw bed snug against the fence, make your cut on each side of the shelves (figure E).
- Cut a 1 x 2 strip to the length of the back edge of each shelf.
 |

 Figure F
|
|  |

 Figure G
|
|  |

 Figure H
|
|
Routing Upright Supports- Mark the location of 6" upright supports on each shelf -- two for each shelf.
- Use a plunge router (figure F)with a straight cutting edge to remove a ¼ groove in the bottom shelf and a 1/4 " groove on the underside of the top shelf.
- Router all the way through the center shelf.
- Building a simple jig will help make the routers consistent. For the jig, temporarily screw scrap wood stops in to sawhorses or work table.
- The router goes inside the jig (figure G) and runs against the stops.
Assembling Shelves - Before nailing edges to shelves, dry fit and make adjustments as needed.
- Run a bead of wood glue along the mitered edge of the shelf lip piece and set into place underneath the shelf (figure H).
- Check the fit as you go by placing the side pieces into position before nailing.
- Use finish nails in a nail gun to attach the lip to the shelf shooting down through the shelf. Shoot nails every couple of inches down through the shelf into the lip. Then, shoot more nails through the front of the lip at an angle, crossing the other nails.
- To finish the shelf, attach the side pieces with glue and nails as before.
- Finally, run a bead of glue along the one by two strip which acts as a cleat to nail the shelf into the wall studs
- Set the back edge of the shelf onto the cleat, then nail together with nail gun. Allow wood glue to dry thoroughly.
Vertical Supports - Rip plywood to the width of your routers in shelves (6").
- Use a round-over bit on the plunger to round all edges of 6" plank.
- Use bar clamps to hold your work in place, then router both sides of the wood. Make a second pass if necessary to smooth out any rough spots.
- Once the edges are done, cut the supports to length (in this case, 23").
- Go over all flat surfaces of shelves and supports with a random orbital sander for a smooth finish.
Sand and Stain- Go over the shelf edges lightly by hand with fine-grit sandpaper. Be careful on the corners, taking care to make sure the edges are "crisp".
- Stain the shelves with a water-based stain. Apply with rags, wiping on in the direction of the grain and rubbing it in well. Stain both sides.
- To get into tight corners (figure I), wrap a rag around the point of a screwdriver, then apply.
- Allow stain to dry, then apply a second coat as before. Fill visible nail holes with wood putty that matches the stain.
 |

 Figure J
|
|  |

 Figure K
|
|  |

 Figure L
|
|
Mounting Shelves on Wall- Mark position of the wall studs with blue tape.
- Measure the height of the bottom shelf and transfer that mark across your wall using a level.
- Hold the shelf against the wall on your level line (figure J) and transfer stud marks onto the cleat underneath the shelf
- Use a countersink drill bit to pre-drill holes (figure K) on the marks. Pre-drill all shelves at once.
- Mount the shelf on the wall by securing 3" screws into each stud. Use a telescoping pole to provide extra support for your shelf as you drill 3 evenly spaced holes into the routered portion of the bottom shelf.
- Set upright shelf supports into the routers and secure with screws from underneath.
- Pre-drill holes in upright supports for metal shelf pegs. Slip pegs into the holes to support the shelves above (figure L).
- Add the middle shelf slots down on the vertical supports. Add the top shelf, making sure all are aligned correctly. Drill into the vertical supports to secure.
- Add screws through the top for stability.
- Once all your shelves are in place, screw 1 x 2 ledgers into the wall at desk height into the studs.
Professional Installation of Shelves: $2,000 Cost of Materials: $345 Amount Saved by Doing It Yourself: $1,655
|
|
|
|