DIY Network

Versatile Bookshelves: Cutting the Bookcase Parts From "Freeform Furniture" episode DFFF-105

Host Any Devers introduces the finished bookshelf and explains the components involved in making the 3' x 7' piece of furniture. Then she cuts (on the table saw) all the parts for the bookshelf out of 3/4" plywood that has been pre-veneered with walnut hardwood.

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	Host Amy Devers creates bookshelves that hold a lot of books...
	but maintain a sense of lightness.

Materials:

3/4" plywood with walnut veneering
Cross-cut system
Pre-glued walnut edge banding
Pencil
Small roller
Edge band trimmer
Dowels
Masking tape
Dowel centers
Stainless steel tubes
Stainless steel washers
Threaded rod
Threaded insert
Screws
Nuts
Large forstner bit
Small forstner bit
1/2" drill bit
220-grit sandpaper
Cloths
Tent
Lacquer
Lacquer thinner
Sealer
400-grit sandpaper
Synthetic steel wool
Wood glue
Clamping blocks
Small paint brush
Metal chop saw
Safety glasses

Tools:

Table saw
Circular saw
Hot iron
Doweling jig (aluminum or wood)
Drill
Combination square
Tape measure
Clamps
Awl
Plastic mallet
Orbital sander
Professional spray gun
Disc sander

	Figure A
	Figure B
	Figure C
	Figure D
	Figure E

Cutting the Bookcase Parts

1. Do your calculations to see how much wood you need and then create a cut list (figure A) to figure out how to maximize your material.

2. Set the table saw blade and fence and cut the shelf pieces to width making sure to keep the wood flat and square against the fence. The fence simply helps guide the work piece (figure B).

3. Make the rest of the cuts for the shelves.

4. Rip the shelf supports to width and the pieces to construct the plinth.

5. Once all the parts are cut to width, cut them to length on the cross cutting system. It has its own table and a fence to rest your work against, as well as a guide rail to run the circular saw on for a nice accurate cut (figure C). If you don't have a system like this at home, clamp a straight edge to your work piece and use that to guide the edge of your circular saw.

6. Place the shelf component on the table so it's against the fence.

7. Line up the mark along the edge of the guide rail for the shelf piece.

8. Using a circular saw, cut it to length (figure D).

9. Repeat the same process for the remaining shelves.

10. To finish the cutting, cut the shelf dividers and the plinth to length. Cut some corner braces and mounting blocks (figure E). The corner braces serve to reinforce the butt joint and the mounting blocks when attached to the plinth, and gives you something to screw up into the bookshelf.

    Note: A plinth is basically a rectangular base. The plinth serves two purposes--it elevates the piece and it serves mainly to reinforce the shelves.

11. Use the table saw to cut these.

12. With the miter gauge and the blade on the table set, cut the mounting blocks. The blocks will be used to fasten the plinth to the bottom of the bookshelf.

13. Next, adjust the miter gauge to 45-degrees and rip the corner braces to length and width. The braces will help strengthen the plinth.

In the next segment Amy demonstrates the edge banding and joinery.

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

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

Ulmia GmbH
Website: www.ulmia.de

Woodcraft
Website: www.woodcraft.com

Shop Equipment
Eagle Manufacturing Company
Website: www.eagle-mfg.com

Lumber
Timber Products
Website: www.timberproducts.com

Spray Equipment
Apollo Sprayers Int'l. Inc.
Website: www.hvlp.com