Bookcase Project – Original Woodworking Bookcase Plan & Design 1

well I am really pleased this looks wonderful terrific you like little bird sculptures cute alright I may be in Rogers and I'm less syczyk we just built this bookcase in our shop and today we're going to show you how to do it you know it may look difficult but it's actually a series of simple woodworking steps that are easy to learn and once we take you through it step by step you'll be able to build shelves like this in almost any room in your house so let's get down to the woodshop and get started good idea so this is a model of the bookcase so we're going to show you how to build today I want to take you through the component parts of it we built the shell or carcass out of a a open-air plywood now what that means is that both sides of the plywood are layered with a thin coating a thin surface of solid oak a plywood is an excellent material for this because the bookcase is fairly wide and fairly tall it holds its shape very well it's very strong you also get a consistent kind of surface you're not gonna have to worry about knots or splitting okay then the next thing we did is we then faced it with a face frame and these little thin shelf strips on the verticals and the shelves that's all solid oak and that covers up the the layered edges of the plywood right here we have an adjustable shelf and to accomplish that we've drilled holes all the way up along the side so we can adjust that to varying heights also on the back side we have a door here we'll show you how to construct it and to hang it up here along the top we've got a crown molding two-piece crown molding now we did not put a back on the unit because we've decided we're going to push ours up against the wall we like our back to show through you may may or may not decide to do that but in any case we think this is a very attractive unit so let's go through the steps involved in building it well we found a fun start let's review the steps we're going to go through first we have a real good plan we're going to follow next we're going to cut out all the plywood parts and we're going to make the dado cuts in the plywood parts and drill them for our moveable shelves then we're going to assemble a carcass build and attach the face frame install the molding build the door and hang it put on a beautiful finish now the tools we'll need in addition to ordinary shop tools will be a table saw a dado set a doweling jig and a shaper or router let's get to work to start the construction of our bookcase the first thing we want to do is rip the sides and the shelves down to size now I check the plans and if they're both sixteen inches wide so I set the saw by measuring from the fence to the inside of the blade you always want to cut with the blade on the scrap side of the wood to allow for the thickness of that saw cut which is about an eighth of an inch it's called the kerf okay now even though we've got these extension tables because we're cutting a full four by eight sheet of plywood I'm definitely going to need lessons help and we're going to need this ruler stand which will catch the plywood if it comes off the table yeah that's great okay let's lift her up please we're going to cut this with the good side up right yeah I'll go over there okay now when you're ripping a piece of plywood you want to be sure that the plywood is running smoothly along that fence in fact it's more important to keep your eye on the wood running along the fence than the blade itself okay now the other thing since I'm going to be tailing the board which is catching it as it's coming through that I'm only supporting the weight I'm not pulling the wood through less will do the pushing okay let's get our sleeves rolled out on the uran glasses ready to roll I'm ready to go we finished our ripping of our plywood now we're ready to cut everything to length that's called cross cutting and we're set up here with our miter gauge I've got my mark for the side at six foot three inches that's all lined up a cross-cutting means you're cutting across the grain ripping means you're cutting with the grain since this side is so long I'm definitely going to need some help les can you give me a hand okay great safety glasses check it ready to roll one of the challenges that every woodworker faces from time to time is making multiple parts exactly the same size and that's one of the challenges we have here in our bookcase now one way to do that would be to take your tape mark out the part and then take it to the saw and cut to that mark then I'd have to repeat it again until I had all three parts the same now I can tell you right now from experience that there's no way that anyone can mark measure and cut three different parts and have them come out identical using that method but let me show you a little trick that will solve that problem for you and we'll give you multiple parts you can cut up to a hundred parts this way they're all going to be exactly the same now we're going to use our miter gauge for this cut and we're going to use the RIP fence also it's very very dangerous however to ever have a piece of wood using the miter gauge and the RIP fence at the same time so we're going to use a stop block for safety now I've got the stop block set up here opposite my blade and I've set it exactly at 15 and a half inches which is the length we want for our little movable shelves in the bookcase now for safety I'm going to move the stop block all the way back here so it will not be involved in the cut and it's clamped tightly against the fence then all I need to do is move my stock you can see how it fits right against my stop block and now when I make this cut it'll be exactly 15 and 3/4 and I can make cuts like this all day long at 15 and 3/4 watch says now I've got my set up and I can make repeated cuts like this all day long now that we've got our shells pretty well done let's go to the bench and we'll make our dado cuts in the sides well things are really starting to move along now we've got all our plywood parts cut out for the entire bookcase now we need to treat with our end pieces these are the this is an end piece here here's the end and the finished product we need to make some cuts in it first we need to make a rabbet cut so the top will fit in up here we're going to drill holes for our adjustable shelf brackets like this then we're going to drill make an important dado cut right here in the center and this dado there's the dado cut because we're going to support a lot of weight in this shelf here this dado cut is for this shelf right here and it has to be very very straight right across here we can't have it tilting one way or the other and in order to accomplish that we've got the two side pieces of the bookcase clamped down to the bench and we have a straight edge that goes right across both of them this permits us to make that dado cut in both pieces at the same time and also to assure that they're precisely located just where we want them now in this case we've set up the straightedge five and three quarters of an inch from the bottom we know that our in our router base we've got a space of two and three-quarters inches from the cutter to the edge of the base so if we ride the edge of the router base right along this straight edge our cuts going to be exactly two inches from the bottom and that's just where we want it we've made sure we're nice and square here with our framing square we've got everything clamped down very solidly to the bench so nothing's going to move and when we use the router we have to be careful to use our eye protection and also as you're going to hear in a minute the router makes a lot of noise and so we're going to use some ear protection now we're ready to go and make our cut I've got this router set for the precise depth of this cut we want to end up with a 3/8 inch deep cut and it has to be 3/4 of an inch wide and we're ready to go in order to make dado cuts on the table saw is pretty simple but there are a few things we have to change the first thing we did was take off the upper guard the reason for that is the dado cut is simply a groove in a piece of wood we're not making two separate pieces of wood so that guard has to come out of our way the next thing we did was put in a different table insert that has a wider opening and it permits the dado set to come up through our tabletop then we put the data set itself on and as you can see the data set is simply a series of different blades to cut our blades and a series of chippers in between we set those up to the exact thickness of the dado we want in this case it's 3/4

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