DIY Network

CD Storage System: Cutting Back Panel and Shelves From "Freeform Furniture" episode DFFF-102

In this segment host Amy Devers takes the first step in building the CD Storage System by cutting out the back panel and shelves.

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Construction begins on the CD Storage System by cutting the shelves.

Materials:

Walnut veneered plywood
Walnut veneered glue-backed edgebanding
Pencil
Safety glasses
Scissors
Small roller
Edge trimmer
Small drill bit
Large drill bit
Sanding block with 220-grit sandpaper
320-grit sandpaper
500-grit sandpaper
Square aluminum tubing
Clear satin lacquer
Respirator
High-grade wipe on polyurethane
Lint free rag
Blue tape
Wood glue
2" drywall screws
Spacer
Sex bolts

Tools:

Table saw
Circular saw
Clamps
Iron
Drill
Jig
Orbital sander
Horizontal band saw
Stationary disc sander
Deburring tool
Drill press
Water jet cutter
Sandblaster
Air compressor
Screw gun

	Figure A
	Figure B
	Figure C
	Figure D

Cutting Back Panel and Shelves

1. Cutting the back panel and shelves is the first step. This CD Storage System consists of five wall-mounted units that are less than 6" deep. Because they are shallow, they do not take up much floor space, but each unit holds 600 CDs. The back panel and the shelves are cut out of one piece of walnut veneered plywood.

2. Divide the piece of plywood into two sections using chalk--half for the shelves and half for the back (figure A).

3. Cut the shelves to proper width and then cut them to proper length using a criss cross system which gives a very clean cut and guides the circular saw.

   Note: Amy had a table with a fence that comes with another fence that acts as a guide tail to guide a circular saw (figure B). This gives you a super clean cut with no tear out on the top or bottom. Don't worry if you don't have this system, you can always do it the old fashioned way by clamping a straight edge to your work piece to guide a regular circular saw.

4. With the work piece on the table and the guide rail in place, line up the mark along the edge and using a circular saw, cut the back panel to length (figure C).

5. To make the shelves, take the remaining half of the plywood sheet to the table saw and cut four long strips to the proper width (figure D).

6. Use the circular saw to cut the strips into 14 identical shelves. The shelves are 1/2" smaller than the jewel cases for the CDs.

   Tip: If the CD boxes hang out a little (1/2") over the shelf it makes it easier to file through the CDs with the tip of your finger, and it makes it easier to pull the CDs out of the shelf.

RESOURCES :

Delta Woodworking Power Tools
Website: www.deltawoodworking.com

Festool
Website: www.festoolusa.com

Gladiator Garageworks by Whirlpool
Website: www.gladiatorgw.com

Stanley Tools Product Group
Website: www.stanleytools.com

Lie-Nielsen Toolworks, Inc.
Website: www.lie-nielsen.com

WMH Tool Group
Website: www.wmhtoolgroup.com

Power Tools (Porter Cable)
Porter Cable Power Tools
Website: www.portercable.com

Hand Tools
Garrett Wade Co., Inc.
Website: www.garrettwade.com

The Peck Tool Company
Website: www.pecktool.com

Biesemeyer
Website: www.biesemeyer.com

Saw Blades
Forrest Manufacturing Company
Website: www.vacupress.com

Jogensen Adjustable Clamp Company
Website: www.adjustableclamp.com

Adhesives, Abrasives and Safety Equipment
The 3M Company
Website: www.3m.com

Klein Tools
Website: www.kleintools.com

Power Tool Accessories
Woodcraft
Website: www.woodcraft.com

Ulmia GmbH
Website: www.ulmia.de

Water Jet Services
Flow International Corp.
Website: www.flowcorp.com

Greek Marble, Inc.
1600 San Fernando Rd.
Los Angeles, CA 90065
Phone: 323-221-6624
E-mail: greekmarble@attglobal.net

Woodcraft
Website: www.woodcraft.com

GUESTS :

Elliott Monson
Water Jet Expert
Flow International Corporation
Applications Lab
23500 64th Ave. S.
Kent, WA 98032
Phone: 253-850-3500
E-mail: jbailey@flowcorp.com
Website:www.flowcorp.com