DIY Network

Versatile Bookshelves: Lacquer Finish and Installation of Three Boxes From "Freeform Furniture" episode DFFF-105

In this third segment host Amy Devers applies a lacquer finish to the bookshelves and then installs the three boxes to form the bookshelf.

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	Host Amy Devers applies a lacquer finish to the bookshelves.

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
	Figure F

Lacquer Finish and Installation of Three Boxes

Note: Lacquer is used because it has clarity, depth and a quick dry time.

1. Use 220-grit sandpaper because it is an ideal grade to smooth and remove all the scratches from the surface of the veneer. Go over the walnut veneered plywood surface with an orbital sander making sure to sand with the grain of the veneer (figure A).

2. Go over the surface with a cloth making sure to remove all dust particles.

3. Set up a tent (figure B) to try and keep dust from settling on the wet finish.

   Note: Because of the flat surface that has to be finished a professional spray gun is used. It works on a turbine system. The turbine supplies a steady flow of warm air at a low pressure that mixes with the lacquer in the can and forms a nice controllable spray.

4. Before spraying, mask off the glue joints. Glue doesn't bond well if there is a finish on the wood, so masking off the joint with lacquer tape will avoid any of the finish getting on the parts where the glue will go.

5. With the spray gun set up, turn on the turbine system and apply a thin even coat of sealer onto the work pieces (figure C).

6. Repeat this spraying process on both sides.

7. Let the work pieces sit for a few minutes and lightly sand the surfaces with 400-grit sandpaper until it is smooth.

8. Fill the spray gun with 20 percent thinner and 80 percent lacquer. Apply a wet coat of lacquer to the work pieces, but not so much that the lacquer runs. Be careful to avoid overspray.

9. Lightly hand sand with 400-grit sandpaper.

10. Spray on two more coats of lacquer, allowing a few minutes of dry time between each coat and lightly hand sand with 400-grit sandpaper in between coats.

11. Let the last coat dry for a few hours and then buff the sprayed surface with fine gauge synthetic steel wool, knocking back any uneven surface.

12. Wipe it down with a cloth, and then let the pieces dry for a few hours in a dust free environment.

13. When the lacquer is dry, it is time for the glue up. Remove the tape. The clean joints will help the bookshelf components bond properly.

14. To install the bookshelf, start by putting the wood glue on the joint line (figure D) and in the dowel hole.

15. Spread the glue out evenly and insert the dowels into the holes.

16. For the shelf divider, run a bead of wood glue in the dowel holes and across the surface.

17. Spread it out with a brush, insert the unit into the dowels (figure E), and hammer it with a plastic mallet.

18. Repeat the same assembly process for the other side of the shelf.

19. Join the shelf section to the dividers.

20. Use cauls to help protect the wood and clamp everything into place (figure F). The cauls will help distribute even pressure.

21. Use this exact same process for the second box that will sit directly on top of the bottom box and plinth.

22. Once the big boxes are glued up, glue up the plinth. Run the wood glue on the side of the plinth and in the holes. Insert the dowels, hammer them into place and join the side and front of the plinth together.

23. Set the plinth down and clamp it into place.

24. Once everything is glued, let it dry.

In the final segment Amy assembles the bookshelves.

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