| Hanging Bookcase -- Assembly |
From "Wood Works"
episode WWK-110 |
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With the bookcase elements made, the dovetail joinery cut and the shelves made, the bookcase project is well under way. With the major pieces made, actual assembly can begin. Materials: Bookcase and shelf elements
1/4" thick maple plywood
Woodworker's mallet
Table saw
Drill press
Wood biscuits
Belt sander
Cabinet scraper
Woodworker's hand tools -- scrapers, sanding block, sandpaper, etc.
Slow-setting wood glue
Clamps
Carpenter's pencil
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his website -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, saws, drills, routers, etc. Case and Shelf Assembly With the multiple dovetail joints, the glue-up is fairly complex. But following the steps and tips outlined below should make the project go smoothly. Tip: Whenever assembling a piece as complex as this one, always begin with a dry-fit to make certain that all of the pieces fit together properly. In this case, this will provide the opportunity to ensure that the dovetails all line up and fit. Tip: For assembly, use a slow-setting glue. This will allow plenty of working time for assembly, free from panic that the glue is hardening before all steps and final adjustments are complete. Tip: Beginning with a loose assembly of the case elements, and tapping the dovetails partially together (figure A), you'll avoid fighting the tight fit of the dovetails and will have plenty of room to brush the glue into the dovetail openings. Steps: - With the case elements loosely assembled as described above, apply glue to the biscuits and shelves, and insert the biscuits into their slots (figure B).
- Apply glue between the dovetail joints using a small paintbrush (figure C).
- With the glue applied to all of the joints, gently tap the top and bottom elements (figure D) to bring the joints together and begin firming up the case assembly.
- Set the shelves in place inside the case (figure E), and gently tap the side pieces to bring the case together.
- Tap all of the joints together to complete the case assembly, then clamp the assembly together (figure F).
- Use plenty of clamps to ensure adequate and uniform pressure to all of the glued surfaces (figure G).
Cutting the Back Panel; Prepping the Surfaces As the glue is drying in the assembled case, it's a good opportunity to cut the maple plywood panel for the back of the bookcase. Steps: - Using measurements taken from the assembled bookcase, lay out markings on the maple plywood stock for cutting the panel (figure H).
- Use measurements taken from the inside corners -- not the middle. The corners will remain fixed, whereas the middle sections could bow out or toe in slightly. To compensate for any such variations, a hand planer can be used later to shave off any excess wood from the panel's edge to ensure a tight fit.
- Once you've taken measurements, cut the panel piece to size on the table saw (figure I).
- Once the glue in the assembled case has had a chance to dry, some power tools and hand tools can be used to smooth the wood surfaces. First, a belt sander is employed to remove excess glue, smooth rough spots and bring out the appearance of the dovetails (figure J).
- After the belt sander, a cabinet scraper is a useful tool for fine-smoothing (figure K). In our demonstration, a #80 cabinet scraper was used to shave off thin layers of wood and remove any scratches left by the belt sander (figure L).
- Once the outside of the case is smoothed and cleaned up, the same is done to the inside surfaces. A hand scraper is ideal for getting into hard-to-reach surfaces to remove rough spots and surface imperfections (figure M).
The Back Panel and Mounting Plate With the rough spots and excess glue removed from the wood surfaces, the next steps include installation of the plywood panel and the mounting plate for hanging the finished bookcase on a wall. Steps: - Earlier, a rabbet was routed on the back of the case for installation of the back panel. A stop-rabbet was cut so that the rabbet wouldn't cut into the dovetails. Therefore a hand chisel is used to carefully chisel the corners square (figure N) so that the corners of the panel will fit properly. The chiseling technique involves making a series of small cuts across the corner section, then carefully removing the excess wood by means of a lateral cut with the chisel blade.
- At the table saw, a piece of maple stock is cut 3-1/2" wide and the same length as the shelves, to use as the mounting plate for hanging the bookcase.
- Holes are predrilled in the mounting plate, which can later be used for attaching the bookcase to the wall. The holes can be countersunk so that the screws will be flush with the wood surface.
- Once the holes are drilled, the mounting plate is glued into the top of the section of the back of the bookcase (figure O).
- With the mounting plate installed, the back panel can be dropped into the rabbet at the back of the case (figure P).
- Once the panel has been checked for fit, it can be glued in place using yellow wood glue (figure Q and R).
- Once the panel is in place, clamps and wood strips are used to hold the final assembly secure while the glue dries (figure S). This presses the panel down into the rabbet, resulting in a strong bond.
The installation of the plywood panel and mounting plate completes the assembly of the bookcase. In the segment that follows, some final touches and wood finish are applied. Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
The Complete Woodworker's Companion
Author: Roger Holmes
Publisher: Watson-Guptill
ISBN: 0823008665
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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