DIY Network

Assembling the Magazine Rack All the pieces of the magazine rack are assembled. From "Freeform Furniture" episode DFFF-111

Host Amy Devers finishes the magazine rack by attaching the ledger strips to the side panels, assembling the box, placing the feet and screwing on the plywood caps.

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Host Amy Dever assembles the magazine rack.

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

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Assembling the Magazine Rack

1. The first step in the assembly is to attach the ledger strip on the inside of the side panels.

2. With the side panel and ledger strip clamped to the table, measure to make sure of the correct placement (figure A).

3. Drill three countersink holes in the ledger strip for screws. A countersink is used to make the screw sit flush with the surface of the plywood.

4. Insert screws into each hole (figure B). Repeat the entire process on the other side of the panel.

5. Once the ledger strips are in place, you can put the rest of the box together. Lay the end panel on the table with the dado groove face up and attach the two side panels.

6. Join the dados on the other end (figure C). Turn the box back up right and secure the dado grooves.

7. Clamp the box together at the dado joints, checking to make sure that both sides are secure and even.

8. Measure for square. On the boxes, one way to check for square is to measure diagonally from corner to corner (figure D). If the two measurements are the same then the box is square. This will insure that the finished piece is not slanted.

9. Once the box is clamped together and is nice and square, the whole thing is going to be held together with screws. You can't just drive a screw in straight because there are so many layers in the plywood. It is very dense and if you try and drive a screw straight in, it is likely to split. So what you need to do is pilot the hole. That is basically drilling a little hole before the screw goes in.

10. When selecting a drill bit, be careful to select a drill bit that is just a little less in diameter than the shank of the screw (figure E). The screw needs to be centered in the dado joint so you can rest a combination square on top of the joint. That serves as a guide and you can drill the holes directly under it and into the joint.

11. Insert the first screw and continue the process of measuring, drilling pilot holes, and driving screw in the top joint all around the box. When all four screws are in place, remove the clamps and flip the box over so that the beveled corners are sitting on the table.

12. Continue the process of measuring, drilling pilot holes, and driving screws in the top joint all around the box.

13. Repeat the same steps to insert the remaining four screws. As you are drilling, hold the side panel steady with your hand since it no longer clamped into place.

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