Woodworker's Journal 2004 Spring, страница 21

wooden plugs (pieces 9), as shown in Figure 2. Make the plugs by ripping strips from your 3/8" plug stock and crosscutting the strips Into plugs. Pre-drill pilot holes through the rails and then, with a chisel, cut 3/8" square mortises over the holes to receive the square plugs. (Note: Make these plug holes 1/4" deep.)

Notch the ends of all the shelves by gang cutting them in pairs using the table saw and your miter gauge. See the Elevation Drawings to lay out the differing dimensions and shapes of the notches — those on the top and bottom shelves are deeper than the middle shelves. After checking the fit of the top and bottom shelves in the rails, apply glue in the rail mortises and insert the shelf tenons. Secure them with the screws, then glue the plugs in place.

All that stands between you and the finishing room is to make four rows of shelf pin holes in the stiles of each side assembly for the two adjustable shelves. Refer to the Elevation Drawings again to determine the starting and stopping points of these rows. Drill the holes using a piece of pegboard as a template and with a sharp brad point bit fitted with a depth collar. Clamp the template evenly in place on each stile before boring the holes.

Give all the project surfaces a thorough sanding up to 220 grit before proceeding with finish.

A Safer Stickley Finish

Stickley developed a unique method of fuming white oak with ammonia to create a glowing aged and mellow color. Mimicking the unique look of the Stickley finish was a challenge I took seriously. I used Bartley's honey gel stain to approximate the same fumed effect with much less fuss and danger. It's also convenient for staining vertical surfaces without the drippy mess. Just be sure to wipe all the excess gel out of nooks and crannies. Protect the wood with a few coats of satin varnish — the gel variety goes on smoothly and won't sag if you accidentally apply too much. It produces a rich luster that is very much in keeping with the Arts & Crafts tradition. The shelf supports (pieces 10) are the brass plug-in type; install them after the finish dries.

This is such a classic bookshelf that I'll wager you're making a second or third as soon as this one finds

a prominent spot in the living room or den. @

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Matching the traditional fumed Stickley finish with less toxic alternatives is a challenge. I found that using a gel stain followed by a complementary gel varnish does the job quite handily — and without the need for a fuming tent, chemical gloves or a respirator.