Materials:
1" x 12" lumber
circular saw
power drill/drill bits
router
3/8" round over bit
3/4" straight bit
tape measure
carpenter's square
finish nails
wood putty
wood glue
stain/oil based polyurethane
sandpaper
Steps:
- The pieces needed for this project were cut out of 1" x 12 " aspen lumber. The pieces consist of three shelves, which measure 62-3/4 inches, two side pieces that measure 30 inches and two center pieces that measure 12-1/8 inches. Cut all the pieces using a circular saw. All ends of the boards will need to be squared, so use a cutting guide to helpe ensure straight cuts with your circular saw. If your shop is equipped with a radial arm saw have at it.
- This step uses a router. All of the front edges of the boards will need to be softened with a curved edge, and to do this I used my router table and a 3/8 inch round over bit. I passed the wood through the router table, then flipped the board , and did the other side of the same edge, and this creates a soft, round edge. Once you have rounded the edge, sand the entire board with a 150 grit sandpaper, and remove the dust with a tack cloth.
- To assemble the shelves the side pieces will need to have a rabbit slot routed (a rabbit is a groove that allows the shelf to slide into position and be secured). For this I used my router again, this time holding by hand and using a 3/4 inch straight bit. To position your rabbits, place the two sides on a work table. From the top, measure down 2-1/2 inches and make a mark. From the bottom, measure up 1-1/2 inches and make a mark. For the middle shelf, find center between the first two positions and mark.
- To rout the rabbit, measure the base of the router from the center of the bit to the edge of the foot plate (featured one was three inches). Transfer that measurement from the marks you made on the sides and make a mark. This will be your router guide mark. To insure a straight cut, lay a squared board at the new mark, this will be the guide board for the router. Set the router depth at 1/4 inch and make a pass. Then move the guide 1/16 inch and make one more pass.
- The three shelves also need a rabbit groove (this will allow the center support to slide in and be secured). Find the center of the top shelf and the bottom shelf and run a rabbit on the bottom of the top shelf, and at the top of the bottom shelf (it will all make sense when you do it!). For the center board find the center and run a rabbit on both the top and the bottom (reduce the router depth to 1/8 inch ). Sand all rough edges.
- Now it's time to put it all together. Lay the sides on a flat work space (you may need another pair of hands to assemble the shelf). Slide the bottom shelf into the bottom rabbit of the sides (apply a thin bead of glue in the rabbit before assembling). Secure the shelf by nailing finish nails through the side and into the shelf (drill pilot holes to reduce splitting the wood). Repeat for the other two shelves.
- Once the shelves are secured, slide the bottom center into position and attach with finish nails through the middle shelf. Then slide the top center into position . Secure from the top shelf with finish nails. Set the nails and fill the holes with wood putty. Sand and tack off the surface. Dust off the entire shelf and then apply a atain color of choice. Allow to dry and follow with two to three coats of oil based polyurethane.
Note: A gel stain works well for the finish. It allows you to stain underneath the shelf without drips or runs.
