DIY Network

Cutting the Parts The magazine-rack project begins by cutting the parts and dado grooves. From "Freeform Furniture" episode DFFF-111

Host Amy Devers cuts the parts for the magazine rack, demonstrates how she made the jig and cuts the dado grooves into the side panels.

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Host Amy Devers cuts the parts for her ultra modern magazine rack design.

Materials:

Pre-finished colored plywood
Cut list
Tape measure
Safety glasses
Stop block
Clamps
Wax pencil
Fence with 2 slots--(1" apart and small piece of stainless steel bar stock inserted in one)
Dado blades
Ruler
Pencil
Template for cutting window
Drill bit as large as jigsaw blade
Double stick tape
Flush trimming bit
45-degree router bit
Blue tape
Lint free cloth
Wipe-on polyurethane
Sharpie
Stainless steel bar stock
Abrasive cut off wheel
Welding jacket
Earplugs
Face shield
Pre-fabricated feet
Countersink bit
Screws

Tools:

Table Saw
Cross-cut sled
Drill
Jigsaw
Router
220-grit hand sander
Disc sander
Random orbital sander
Combination square
Screw gun
Awl

Cutting the Parts

Note: Colored plywood (figure A) was chosen for this project because it has a sleek modern look and it is pre-finished. It comes in full 4 x 8 sheets and costs approximately $200 a sheet and can be purchased at specialty plywood suppliers.

1. Make a cut list. First, cut all of the pieces to width. Take the plywood to the table saw and cut the bottom and sides, and then cut the ledger strips that the stainless steel slats will hang on.

2. Cut the caps (figure B) that will cover the exposed ledger strips and steel slats.

3. Cut the parts to length using a crosscut sled (figure C). It has runners on the bottom that slide along on the tracks on the table saw and it holds your wood perfectly perpendicular to the blade, keeping it from pivoting or shifting while you are feeding it through so you end up with perfect 90-degree cuts.

Figure A

Figure B

Figure C

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