DIY Network

CD Storage System: Aluminum Brackets From "Freeform Furniture" episode DFFF-102

Host Amy Devers creates the unique aluminum brackets and demonstrates how the metal CD dividers were made.

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Host Amy Devers creates the metal brackets for 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
	Figure E
	Figure F
	Figure G

Aluminum Brackets

1. To create the aluminum brackets, slice off sections of 4" x 4" aluminum tubing using a band saw. Once the tubing is clamped in place, turn on the horizontal band saw and lower the blade onto the tubing (figure A).

   Note: If you don't have a horizontal band saw, it is possible to cut aluminum with either a vertical band saw or table saw and the right blade, or you can even use a hacksaw if you want a good workout. The great thing about a band saw is that the weight of the cutting head does all the work.

2. Sand the saw marks off using a stationary disc sander (figure B).

3. The sander will get rid of the majority of the burrs. You can use a deburring tool (figure C) to get rid of the extra burrs.

4. You are now ready to drill the holes in the shelf brackets using a drill press. Set up a jig so that the drill bit hits the brackets in the same place every time (figure D). There are two holes per bracket.

   FYI: The metal alphabet dividers were made by a metal fabricator. The coordinates of the drawings were input on the computer. The drawings came up on the computer monitor (figure E) and a program was created that the water jet machine could read.

   Water jet technology uses silica crystals mixed with 55,000 pound per square inch of metal pressure. It easily slices the metal. The program is then sent over to the machine and the jets are turned on. The computer talks to the machine and tells it where to go next (figure F).

5. Once the alphabet dividers are finished, you need to give them a finished look. Use a sandblaster, which will provide a textured finish. Wear protective gloves and position the work piece so you can blast every surface.

6. Sandblast the pieces with a nozzle that shoots the glass beads (figure G). The glass beads fall down into the bottom where they are re-circulated back through the nozzle.

7. Raw aluminum is very susceptible to oxidation. Spray a coat of clear satin lacquer on the brackets. Make sure you are in a well ventilated area and wear a respirator when spraying.

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