Project #1 – Classic Wall Shelf
PLEASE SCROLL TO THE BOTTOM OF THIS PAGE FOR PROJECT DIAGRAMS
Side Supports
Quantity: 2 – Both pieces are cut from 1 larger piece
Final Dimensions: 7/8” x 4” x 18” – you will need only 1 piece this size
Material used: 1 1/16” thick red oak
Steps:
1. Locate a piece of stock to complete the side pieces
2. Cross-cut to rough length of 19”
3. Joint one edge
4. Rip cut to 4” wide
5. Surface plane board to final thickness of 7/8”
6. Cross-cut 1 end square
7. Cross-cut opposite end to final length (18”)
8. Carefully trace side support pattern. Be sure to position the pattern so that the top edge is aligned with the square end of your stock.
9. Cut out each side support using the band saw and the miter saw as demonstrated – leave pencil lines slightly visible!
10. Remove all saw marks and sand up to pencil lines with the oscillating spindle sander, the 1” belt sander, and normal 120 grit sandpaper
11. Shape outside edges with router as demonstrated – use router pad for safe operation
12. Sand side supports thoroughly, write your name on them, and store in your locker
Top
Quantity: 1
Final Dimensions: 7/8” x 5” x 19”
Material Used: 1 1/16” thick red oak
1. Locate a piece of stock to complete the top piece
2. Cross-cut to rough length of 20”
3. Joint one edge, Rip to 5” wide
4. Surface plane board to final thickness of 7/8”
5. Cross-cut 1 end square, Cross-cut opposite end to final length(19”)
6. Shape both ends and the front edge with ¼” roundover bit in router – do not round over back edge! Use router pad for safe operation
7. Sand top piece, put your name on it, and store in your locker
Back Stretcher
Quantity: 1
Final Dimensions: 7/8” x 3” x 15”
Material Used: 1 1/16” thick red oak
Steps:
1. Locate a piece of stock to complete the back stretcher (scrap area)
2. Cross-cut to rough length of 16”
3. Joint one edge
4. Rip to 3” wide
5. Surface plane board to final thickness of 7/8”
6. Cross-cut 1 end square
7. Cross-cut opposite end to final length (15”)
8. Run the bottom edge of the back stretcher through the shaper to create a profiled edge
9. Sand back stretcher, put your name on it, and store in your locker
Peg Board
Quantity: 1
Final Dimensions: 7/8” thick x 16 3/4” long (You will NOT rip this
board to width – just find a piece that is AT LEAST 4” wide)
Material Used: 1 1/16” thick red oak
Steps:
1. Locate a piece of stock to complete the peg board. This piece must be at least 4” wide – do not rip this board to width as it may be possible to yield 2 peg boards from one piece of stock
2. Surface plane board to final thickness of 7/8”
3. Lay out arched peg board pattern and trace with a pencil – be sure to mark all hole centers
4. Cut peg board with band saw and miter saw as demonstrated – leave pencil lines slightly visible!
5. Remove all saw marks and sand up to pencil lines with the oscillating spindle sander, and the horizontal belt sander – be sure to produce smooth arcs
6. Drill ½” holes 5/8” deep at each peg location
7. Drill 3/8” counterbores 3/8” deep at each screw hole location
8. Shape the front face with 1/8” roundover bit in router – do not round over the back face! Use router pad for safe operation
9. Sand peg board, put your name on it, and store in your locker
Assembly
1. Dry fit all pieces and check for squareness and proper fit.
2. Mark biscuit joints on the back stretcher and side supports as demonstrated – use biscuit joiner to cut slots
3. Clamp the side supports to the back stretcher with glue and biscuits – be sure to check alignment of joint, check that the top fits well (no wobble or gaps), and that the peg board fits well
4. Align peg board with side supports, clamp in place and predrill 9/64” pilot holes at each of the screw locations through the peg board and into the sides
5. Apply glue and fasten the peg board to the side supports with 1 ¼” screws
6. Apply glue to top edge of side supports and back stretcher, align and center the top piece, clamp if necessary, and fasten using 1 ¼” brads
7. Write your name on the back of your project at this time!!!
8. Apply glue with a Q-tip and tap in 4 buttons or plugs to cover screw heads.
9. Apply glue with a Q-tip and insert 3 shaker pegs – be sure to push or tap them all the way in.
Final Steps
1. Sand project thoroughly with 220 grit sandpaper
2. Stain project as desired
3. Apply colored wood putty to nail holes, cracks, imperfections, etc.
4. Apply 2 coats of lacquer – sand with 600 grit between coats
5. Attach two sawtooth hangers to the back – 16” apart
CONGRATULATIONS!