Red Team Activity Journal (1 p.m. - 3 p.m.) - After creating dadoes to support the shelves, the Red Team uses a hand saw to cut four pieces of track shelving to 72" inches each.
- Next, the team sands each individual piece with the power hand sander to get rid of any blemishes.
- With no detail overlooked, the team decides to stain the dadoes with a walnut stain (figure A) before nailing the track shelving into place and prevent bare wood from being seen between the shelving.
- Next, the team slides the track shelving into place and secures with nails.
- Three shelves are cut to 35" long and sanded with a power hand sander. The team checks the fit of the shelves before moving on.
- The team places side, top and bottom pieces into the rabbets, securing with nails (figure B)
- Wood filler/putty covers the nails and the bookcase is measured for the back surface piece.
- The team measures and cuts 1/4" finish grade oak plywood using both miter and table saw, then nails the pieces to the back of the bookcase (figure C) with finishing nails.
Ed's Tip: Wood filler/putty comes in a variety of colors. For best results, first stain wood, then add filler/putty to match the wood stain. Blue Team Activity Journal (1 p.m. - 3 p.m.) - As the Blue Team puts its collective noses to the grindstone, their original concept begins to really take shape. First, the team uses a hand saw to cut a notch for a 6' long 1" x 3" that will fit vertically along the middle of the front surface.
- Next, the team secures the piece with screws (figure D) and uses a router to shape the 1 x 3s used for the door frames.
- A 1" x 3" piece is cut for horizontal positioning, then the team measures and cuts two 31" pieces. The 31" pieces are added to both sides of the vertical 1" x 3", creating a notch for the horizontal piece (figure E). The same steps are repeated for the back frame.
- The team cuts 45-degree angles to create a door frame from 1" x 3" pieces. The pieces are routed a second time to create a larger bedded area where plywood will be placed.
- Aluminum is cut into small squares that will be used to cover the area where a threaded metal rod will secure the doors, and the team drills 1/2" holes into the centers.
- Eight 15" pieces are cut for the sides of the bookcase (figure F) and are screwed into place.
- The team cuts 6" x 18" pieces for the remaining side areas, top and bottom of bookcase.
Want to know more about the products used on Warehouse Warriors? Click here for a complete list of tools, materials and supplies available to our teams.
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