DIY Network

Versatile Bookshelves: Assembling the Bookshelf From "Freeform Furniture" episode DFFF-105

In this final segment host Amy Devers finishes the bookshelf by attaching the three boxes together and assembling the units together.

advertisement

	Host Amy Devers completes the bookshelf with cantilevered...
	shelves that are strong and graceful.

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

Assembling the Bookshelf

1. We have a threaded rod which runs from the underside of the top shelf all the way down through the sections of the bookshelf. Stainless steel tubing goes over the threaded rod and acts as a stabilizer between the two shelves and is sandwiched by the wood. Finally, washers protect the wood from the stainless steel tubing.

2. Cut the threaded rod and the stainless steel tubing to size on the metal chop saw (figure A). It has a blade that is specially designed for cutting metal. If you don't have one of these saws at home, you can have a metal fabrication shop cut your metal, or you can do it with a hack saw.

3. Mark the length of the threaded rod at 31-1/2" and the stainless steel tubing at 14".

4. Clamp it in place and cut the tubing to length on the metal chop saw.

5. Cut the threaded rod to the proper size.

6. Clean the cut edges of the threaded rod and the stainless steel tubing using a disc sander to remove any metal burrs. It is important as you sand to constantly rotate the work piece (figure B). If you don't have a disc sander, you can use a metal file to clean up the edges.

7. To assemble the bookshelf, screw the mounting blocks in place on the plinth.

8. Pre-drill holes in the tops of the mounting blocks to attach the bookshelf and the plinth.

9. Attach the corner braces (figure C) which help to reinforce the joints on the plinth.

10. Attach the plinth to the bookshelf assembly and begin by centering it in place. Clamp the unit to stabilize the position of the plinth. Finally, screw through the pre-drilled holes on the mounting blocks and into the bottom of the bookshelf.

11. Make sure to select screws that are the proper length so that they don't protrude through the wood.

12. With the top section of the bookshelf on the work table, install the threaded inserts into the holes made earlier with the forstner bit and tighten them in place.

13. To begin the installation, run the threaded rod into the lower section of the bookshelf and install a washer to help protect the wood.

14. Next, the stainless steel tubing goes over the threaded rod acting as a stabilizer between the two shelves (figure D).

15. Add another washer to protect the top section and send the threaded rod through the hole.

16. Add a washer, then the stainless steel tubing.

17. Tighten the rod which runs through each section of the bookshelf into the threaded insert on the underside of the top.

18. Place a nut and washer on the end of the threaded rod and secure the entire structure into one unit.

19. Repeat the same assembly process for the rest of the shelving unit.

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