500 CD Shelf Unit: Step By Step

http://farm6.staticflickr.com/5491/10791398196_3d2131ce33_z.jpg

This project started out as a spreadsheet rather than a drawing; a series of measurements and calculations starting with the dimensions of a CD jewel case and the envelope of available space for the unit. This yielded dimensions for the dado placement for the shelves. I don’t have a table saw, so the rip cuts were made with a circular saw and straight edge.

I used a couple of pocket screws to fasten the uprights together temporarily.

Then I laid out the dado positions:

Next I routed out the dadoes with a jig I made for an earlier project. I inserted a piece of scrap in the first dado to make it easier to slide the workpiece to each new dado position.

The uprights with completed dadoes (now separated again)

I wanted to inset the back, so I used a rabbeting bit to rout a 1/2” x 1/4” deep rabbet in each upright:

The first dry fit:

I found, to my disappointment, that the shelf lengths were a tad less precise than I would have liked. I clamped a makeshift scrap-ply extension to my miter saw and used a speed square as a stop. Now the shelves were nice and uniform, if maybe an eighth shorter than I had planned.

Another lesson learned.

Edge banding next:

Trimming and easing the edges:

Next: Prefinishing the parts.
I predrilled and drove finish nails into the ends of the shelves. This allowed them to be suspended on long ply scraps so I could finish both sides.

I decided to try a home-brew of BLO, gloss poly and Mineral Spirits. People seem to have pretty strong opinions about this. In the end, I was pleased with the results. This is the first coat:

Trimming the uprights to final length:
It’s a good thing I saved this for this late in the project; I decided to alter the design a bit.

The Glue-Up
Getting 13 horizontals into their dadoes – with everything square – within the working time of the glue makes a novice like me nervous. I decided to clamp down guides to keep the first side, the top shelf and the bottom shelf square before I applied any glue. I also drew lines on the assembly table (a hollow-core door on sawhorses, actually) during the dry-fit that helped me to position the shelves in approximately the right alignment to mate with the second upright during the glue-up.

I used an absurd number of clamps for this

It may have been overkill, but all that prep made the process smoother than I had dared to hope. So much so that I even took a photo or two:

Adding the second upright:
This was a little tricky. I got the first four horizontals in their dadoes and applied a loose clamp, then continued working my way to the other end.

Then I applied the rest of my motley collection of clamps. It looked like a Foosball Table.

I used shim wedges and a long piece of ply scrap to apply pressure to the bottom edge:

Cutting and fitting the face frame trim:

Pocket holes to assemble the face frame:

Assembling the face frame:

I positioned the middle slat with the face frame clamped to the unit:

And put in two of the screws with it clamped in place (a right-angle drill attachment came in handy here):

Then a little sanding:

As the holes would never be seen, especially once the shelves were full of CDs, I decided to give myself a break and attach the face frame to the unit with pocket screws:

Fastening the top trim (the unit is 77” tall, so very few people on Earth will ever see these screws)’

Cutting the (prefinished) back panels to size:

Marking the screw hole locations (the spreadsheet numbers were very handy for this):

Finishing the trim and outside surfaces:

Finishing in progress:

Done!

Source: LumberJocks.com

500 CD Shelf Unit: Step By Step