BOOKSHELF: BRONZE LEVEL
PROjEct cENtRE
BRONZE LEVEL
Shelving Unit, Bookcase
cUttiNg LiSt
item
Material
Sides
Top & fixed shelf
Bottom
Adjustable Shelves
Back
Base
25mm MDF
25mm MDF
25mm MDF
25mm MDF
6mm MDF
25mm MDF
MAtERiAL LiSt AND cOStiNg
Material
MDF
Particleboard screw
Shelf supports
tOOL LiSt
Size h x w (mm)
2000 x 396
750 x 385
750 x 390
748 x 385
1900 x 770
850 x 105
420 x 105
Size (mm)
2400 x 1200 x 25
2400 x 1200 x 6
60 x 8g
25 x 6g
5mm
• Router/trimmer - rebate bit or 10mm
•
•
•
•
•
No.
straight and 5mm rounding over bit
Drill/driver
5mm drill bit
PVA glue
Random orbit sander – 120-grit discs
Mitre saw
2
1
50
50
16
•
•
•
•
•
•
•
Unit cost
$80.00
$38.00
$7.75
$5.10
$1.26 (pkt)
No.
2
2
1
4
1
1
2
total cost
$160.00
$38.00
$7.75
$5.10
$2.52
Combination square
Tape measure
Plastic filler
Putty knife
Safety glasses
Ear muffs/plugs
Dust mask
iNtRODUctiON
This sturdy, but relatively simply made, shelving unit is constructed from 25mm thick MDF, as this is the ideal choice
when a painted finish is desired. The adjustable shelves give ample flexibility to accommodate your library of books.
Cutting the pieces to size may be done with a circular saw and straightedge, or why not have it professionally cut and
you would be more than half way there! The joining techniques don’t get any easier - simple butt joints that are glued
and screwed. The lightweight MDF back is concealed by a rebate that gives a clean looking side.
StEP-BY-StEP iNStRUctiONS
1.
Marking out
Lay both side pieces flat, face-to-face, ensuring all edges are flush, and clearly mark the
‘‘top’’ avoid any confusion later. Measure and mark out adjustable shelf hole positions
(see Diagram 1). Square these positions down the front edges. Mark an ‘‘x’’ at the
position of the fixed shelf.
Sides
2.
Drilling holes
Open up the ends, with both inside faces up. Square the lines across the face and use
a combination square set to 50mm to mark the intersecting positions parallel to the
front and back edges. Use a nail to centre punch the hole positions before drilling 5mm
diameter holes to 10mm deep.
3.
Rounding over
A 6mm rounding over bit fitted to your trimmer or router is used to soften the edges of
the sides, top, bottom and shelves. Note: Routing is only done along the front edges of
all pieces.
6mm
4.
Rebating
A rebate is used to conceal the edges of the 6mm MDF back. Set up a router with a
10mm straight cutter to cut a 6mm wide and 10mm deep rebate. The guide fence will be
needed to achieve a 6mm wide parallel cut.
Rebate
5.
Bottom
Side
fixed shelf
Assembly
Glue and screw the top, bottom (see Step 6) and fixed shelf to the ends by drilling a
5mm clearance hole through the sides, followed by a 3mm pilot hole into the ends of
the adjoining pieces. 60 x 8g particleboard screws are used. Tip: Using a spacer block
slightly thicker than the rebate depth (6mm) will help with assembly (as shown).
Side
6.
Rounded corner
Bottom
Side
A touch of detail
The corners need to be rounded over before the bottom is fixed in place. Warning: Do
not use the router for this step. This is safely done by hand with a block plane, rasp or
coarse abrasive paper wrapped around a cork block. The radius should match that of the
adjacent side.
7.
Mitre
Bottom
Mitre base
Use the router to round over one long edge of the base pieces then mitre to length.
Cutting the mitres (45° angles) is most accurately done with a slide compound
mitre saw. Attach with glue and 40mm nails. Masking tape will hold the mitres
secure until the glue dries.
Side
8.
Back
Side
9.
The back
Turn the cabinet over face down and carefully position the MDF back into the rebate.
Fasten with 25mm x 6g screws, starting along the bottom. Pre-drill the screw holes with
a 2mm pilot hole. Tip: Angle the screws slightly towards the centre of the sides when
screwing into the rebate.
Finishing touches
Fill all screw and nail holes with a two-part epoxy wood filler, then sand with 120-grit
in the random orbit sander. Sand all edges with 120-grit by hand. Apply one coat of
undercoat/sealer before applying two coats of your favourite water-based satin enamel.
Sand lightly between all coats.