Popular Woodworking 2005-08 № 149, страница 64
t-103/4' 83/4" 83/4" 193/4" -32"- 32"- 63/4" A —j.-- io3/4" C 143/4" E 143/4" E -32"- 63/4" 63/4" 83/4" 123/4" 123/4" -4 Cutting diagram Take care when cutting your plywood because every kerf counts. Shown is my stack of finished shelves. That little pile on top of the shelves is the waste that was left from an entire sheet of plywood. together to determine the depth of the shelves. Getting these factors to work together to produce sensible shelving is trickier than it first appears. So take care if you want to modify this design - small alterations make big differences. I also sought to squeeze out the maximum amount of shelf space from the minimum amount of material. After additional work in CAD, I squeezed it down to this: To build two shelf units and one desk unit, you'll need to buy: • One sheet of 3/4" plywood • Six 8' 2 x 4s • 35 linear feet of 1 x 4s • 70' of edge tape For this investment in material, you'll get 30 linear feet of shelving and a desk - not bad. Construction is simpler than any bookcase I've built. The shelves rest in dados in the uprights. The uprights are prevented from racking by braces that are pocket-screwed into the shelves and uprights. There's no back, no top and no bottom. It was so simple, in fact, that I decided to add some visual interest by cutting curves on the braces and front edges of the shelves. Cutting 85"-long pieces all to the same size is impossible on most table saws. So I gang-cut the pieces on my miter saw. Clamp your mating uprights together and crosscut them simultaneously. This way if they're a little off, they'll still match. We've acquired a few straight bits throughout the years. After testing a few I found that the Woodline plywood bit cuts a dado that was closest in size (.714" wide) to the particular sheet of plywood I bought. (Woodline: 800472-6950 or woodline.com; item# wl-1028-1, $9). Begin Construction I always like to begin a project that uses plywood by first breaking the 4' x 8' sheets into smaller sizes - plywood takes up a lot of room in small shops. Using the cutting diagram at left you first want to crosscut the full sheet into three equal-sized pieces that are 313/4" long. These are a bit oversized so you can trim them down on your saw and remove the factory edges from the plywood. Then you can easily rip the shelves to their finished widths using the diagram as a guide. Now you need to work on the uprights. Dress your stock as true as possible and then cut it to its finished length. Now lay out the locations of all the dados on the uprights. Because these dados are cut at a 7° angle I recommend you mark out every joint to avoid a blunder. Now you should make a few test dados in a scrap piece to find the best bit for the job. Plywood varies in thickness from sheet to sheet. And straight bits designed for plywood come in slightly different diameters, too. Your best bet is to mill a 3/4" x 3/4" dado in a scrap and see how the plywood shelves fit into it. Different Diagonal Dados You need to make two router jigs to cut the angled dados in the uprights - one for the left-hand uprights and one for the right-hand. I know that it seems like you should be able to make just one jig and flip it around, but the geometry doesn't work that way. I like dado j igs that capture the router's base on both sides. This ensures the router won't wander, and it allows me to make the occasional climb cut without the tool jerking severely. Also note that a router with flat edges on its base will make your dado locations more accu- 62 Popular Woodworking August 2005 |
