| Bookcase: Finishing Touches / Final Scores (3 p.m. - 5 p.m.) |
From "Warehouse Warriors"
episode WHW-203 |
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Red Team Activity Journal (3 p.m. - 5 p.m.) - The Red Team cuts an oak border to support the crown molding (added later) and miters the edges to 45-degree angles for a proper fit.
- Wood conditioner is applied to the soft wood used for the project, then the top trim is sanded and nailed to the bookcase top.
- The crown molding is cut at a 45-degree angle with a miter saw and placed atop trim (figure A).
- The team pre-drills holes and nails molding together.
- Clips are fastened to metal shelving and placed at the desired increments.
- Trim is added around each shelf, and "steps" are nailed to the bottom of the bookcase.
- Finally, the team sands and adds trim to shelves, then stains the entire bookcase with walnut stain (figure B).
Ed's Tip: To make decorative shelves functional and attractive, try the following: use molding to line the bottom of the shelf by nailing and gluing each piece an inch apart. The books will sit atop the molding and will be safe from any liquids that might be spilled onto the shelf. Blue Team Activity Journal (3 p.m. - 5 p.m.) - Although the Red Team finishes with time to spare, the Blue Team is racing to beat the competition deadline. With time running out, the Blue Team adds wooden supports inside its bookcase corners.
- Pieces measuring 18" long are cut and nailed along the side of the bookcase.
- The team cuts 16 pieces at a 45-degree angle to make four 35" door frames, then nails the angled pieces together.
- A table saw is used to cut pieces of plywood for the back of the bookcase (figure C), then for the front of the doors.
- Four pieces of plywood are nailed to the back interior of the bookcase, then 1 x 3s are screwed to the middle frame.
- Oak plywood is attached to the door frames using wood glue and staples.
- The team cuts plywood for the interior sides of the bookcase, the uses a saw to cut a notch to fit around frame (figure D). The plywood is secured to the bookcase interior.
- Then, the team uses a 1/2" drill bit to drill a hole in one corner of each door, and square aluminum sheets are screwed into place.
- A hole is drilled into the bookcase where the frames intersect and a threaded metal rod is added. The rod is cut down at the end.
- Shelves are cut to 34-1/2" long. A length of 1" x 3" is cut to fill spaces.
- The team adds 15" interior braces, and aligns with middle braces of the frame. Shelves are placed atop the braces.
- Finally, the doors are pushed onto the rods (figure E) at each corner and secured with nuts and bolts. Screws are used are braces to hold the doors in place. Putty is used to cover the nails.
The Final Moment The Red Team is well-studied in fine craftsmanship -- and received perfect scores in design and execution! Although the judges felt the Blue Team's project demonstrated remarkable creativity, this time it didn't put the team ahead. The Red Team is champion! Score Summary: Base scores are determined using a 1-10 scale, 10 being the highest. For complete details on the judging/scoring process, click here. Red Team Score Total: 285 Blue Team Score Total: 262 Projects are tested for structural safety and local code requirements before being donated to charity. 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. Want to experience the excitement of battle? Click here to apply for Warehouse Warriors!
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