Classic Double-Doored Bookcase
Side Panels
Quantity: 2
Final Dimensions: 3/4” x 10” x 30”
Material used: 3/4” oak plywood
Steps:
1. Cut plywood panel saw or table saw (10” wide x 30” long)
2. Rip to final width (10”)
3. Cross-cut to a final length of 30”
4. Top Rabbet: Select the tops of the panels and cut a rabbet 3/8” deep x 3/4" wide
5. Lower Dado: Mill a 3/8” deep x 3/4” wide dado at the bottom of the panels - the bottom of this dado should be 2 ½” from the bottom of the panel
6. Back Rabbet: Mill a rabbet for the back panel. This rabbet should be 3/8” deep x 1/4” wide
7. Use template provided by teacher to layout ¼” holes for adjustable shelving - Drill holes 3/8” deep
8. Sand all parts of the panel before assembly
Fixed Shelves
Quantity: 2
Final Dimensions: ¾” x 9 3/4” x 23 ¾”
Material Used: 3/4” oak plywood
Steps:
1. Rip cut plywood to 9 3/4” wide on panel saw or table saw
2. Cross-cut to final length (23 ¾”) – make sure both ends are square
3. Dry fit side panels and fixed shelves – check for square!
4. Assemble case with glue – use 4 bar clamps and check for square - Clean up all glue on project and bench
Face Framing
Quantity: 4
Final Dimensions:
Qty. 2 - ¾” x 1 ¾” x 30” – STILES sized to fit your side panels (left and
right) (stiles are the vertical pieces)
Qty. 2 – ¾” x 1 ¾” x 22” – RAILS will be custom cut to fit between left
and right pieces (rails are the horizontal pieces)
Material Used: ¾” solid oak
Steps:
1. Locate enough ¾” stock to complete all 4 pieces – please check scrap rack first. If necessary, plane thicker stock to ¾”. Make sure all pieces are the exact same thickness.
2. Joint one edge
3. Rip cut all parts to 1 ¾” wide
4. Cross-cut 1 end square of each stile and rail
5. Cross-cut opposite end of stiles to final length (should be 30”)
6. Attach stiles with glue and nails with the best edge inward – be sure to have a SLIGHT overhang on the outside edge
7. Cross-cut rails to fit snugly between two stiles
8. Attach rails with glue and nails with the best edge inward
9. Flush trim side and top edges with router as demonstrated – DO NOT TRIM BOTTOM PIECE
10. Sand all wood joints and edges thoroughly
Baseboards
Quantity: 3
Final Dimensions: Qty. 1 piece for front - ¾” x 2 ½” x 28”
Qty. 2 pieces for sides - ¾” x 2 ½” x 12”
Material Used: ¾” solid oak or other scrap solid oak at least ¾” thick
Steps:
1. Locate enough ¾” stock to complete all 3 pieces – please check scrap rack first! If necessary, plane thicker stock to ¾”. Make sure all pieces are the exact same thickness.
2. Joint one edge, rip cut all pieces to 2 1/2” wide
3. Shape top (best) edge with shaper
4. Miter corners to fit using the miter saw - same technique as nightstand
5. Sand thoroughly before attaching baseboards
Attach baseboards with glue and brads
Sand miter joints smooth.
Top
Quantity: 1
Final Dimensions: 7/8” x 12” x 26”
Material used: 1 1/16” solid oak
Steps:
1. Select 1 1/16” stock for glue-up. Glue-up should be larger than the final size of the top
2. Joint all mating edges, reverse annual rings, and clamp
3. When glue has cured, joint one edge of the panel
4. Rip the panel to final width (12”) on table saw – place cut-off in scrap area
5. Surface plane the panel to final thickness (7/8”)
6. Cross-cut 1 end square on table saw
7. Cross-cut the opposite end of the panel to a final length of 26”
8. Shape or router front and sides – do not shape back edge
9. Place top upside down on bench, flip case upside down onto top, align the back edges, center the top left to right, clamp, and attach with six 1 ¼” screws
When baseboards and top are attached, detail the outside edges of the face frame with a 45° chamfer bit in the router as demonstrated.
Adjustable Shelves
Quantity: 2
Final Dimensions: ¾” x 9” x 23”
Material Used: ¾” oak plywood
Steps:
1. Rip cut ¾” plywood to 9” using the table or panel saw – use scrap if possible
2. Cross-cut to length (23”) using the table saw – make sure shelf fits in your bookcase
3. Cut 1/2” x 1 ¼” shelf nosing to fit on front edge of shelves as demonstrated (Use narrow pieces of scrap oak to make shelf nosing)
4. Attach nosing with glue and brads
5. Router top edge of nosing with 45° chamfer bit
6. Sand thoroughly
Door Frames
Quantity: 8 total pieces required – 4 stiles and 4 rails
Final Dimensions: Qty. 4 stiles (vertical pieces) – ¾” x 1 ¾” x 26 1/4”
Qty. 4 rails (cross-pieces) – ¾” x 1 ¾” x 11”
Material Used: ¾” solid oak
Steps:
1. Locate enough stock to complete all 8 pieces – be sure that the stock is all the exact same thickness (3/4”). Surface plane if necessary.
2. Joint one edge
3. Rip cut all parts to 1 3/4” wide
4. Cross-cut 1 end square of each stile and rail
5. Cross-cut opposite end of stiles to final length (should be 26 ¼”)
6. Cross-cut opposite end of rails to final length (should be 11”)
7. Make a half lap joint at each corner as demonstrated using dado saw
8. Glue and clamp frames – check for square
9. Router outer edge with a ¼” roundover bit
10. Router ¼” deep x 3/8” wide rabbet on the inside of each frame
11. Sand all door frames thoroughly making sure the half lap joints are smooth
Back Panel
Quantity: 1
Final Dimensions: ¼” x 23 ¾” x 29 7/8”
Material Used: ¼” oak plywood
Steps:
1. Select ¼” oak plywood stock
2. Rip to 23 ¾” wide using panel saw or table saw
3. Cross-cut to 29 7/8” using cross-cut table saw
4. Check the fit on your case – trim as necessary
Final Steps
1. Sand project thoroughly with 220 grit sandpaper
2. Stain all project components – includes case, shelves, doors, back
3. Apply colored wood putty to nail holes, cracks, imperfections, etc.
4. Apply 2-3 coats of lacquer – sand with 600 grit between coats
5. Attach back panel good face inward
6. Attach door hinges and handles (or knobs) as instructed
7. Install plexiglass or glass (per your preference) with point driver tool
8. Insert shelf supports and install shelves – CONGRATULATIONS!