Red Team Activity Journal (1 p.m. - 3 p.m.) - Three shelves are cut from plywood measuring 3' x 18", 4.5' x 18" and 5.5' x 18".
- The team assembles the shelving unit using a nail gun. The four 2 x 8' legs go on each corner with the short side on the bottom. The front and rear supports are attached to the inside of these legs (longer to shorter from bottom to top) and the 15" side supports go on each side of the front and rear shelf supports. An extra middle support goes on the bottom and middle shelf (figure A).
- The team nails the shelves on top of the shelf supports.
- Next, the team stains several pieces of molding and the shelves (figure B).
- Trim is cut to fit over the front and rear shelf supports.
Blue Team Activity Journal (1 p.m. - 3 p.m.) - The Blue Team cuts a 47" shelf and attaches it on small strips of wood near the top of the inside of the cupboard.
- Castors are attached to the frame on the bottom of the cupboard.
- Next, the team cuts two 23.5" x 70" doors from plywood. The top of one of the doors is cut into an arch, and the team saves the scrap piece.
- The first door is placed upside down on the second door piece and traced. The team cuts the second arched door and saves the scrap piece.
- The remaining front and side crown pieces are cut (figure C). The front piece will have 45-degree angles cut on each side and the side piece will have a 45-degree cut on the front side. Both pieces will have dado cuts along the bottom edge.
- The dado cuts on the crown piecese are aligned with the top corner of the cupboard and nailed in place.
- Next, the team cuts two 46.5" x 22" pieces of plywood for the remaining shelves.
- Using drawer rollers, attach the two shelves underneath the first shelf so that they will roll out (figure D).
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