Background. You may have see my post on making a couple of doors for a bedroom cupboard. Well I decided to add an additional shelf. I have plenty of ply and "other" material to whip one of quick smart but decided to make one using as many tools and skills as possible. So here we go. As I said in the title its possibly only of interest to newbies. In the begining:- With yet another run to In Glass to collect 6m pallet material the task started. I am not sure where the red sports car is! That kept me busy Sunday morning dismantling them and ensuring my neighbours were not sleeping in! Resulting a huge stash of rustic sawn timber Within the pile earmarked for the Otto bin ( bottom Right) were some pieces which had no nails in them so it was these I saved from returning to the earth, well in the short term anyway.
I selected a few that were possibly able to be reused. Pieces about 250mm x 80 mm x 25mm rough sawn Processes to produce usable timber I jointed 1 side and 1 edge of them all Then thicknesses 1 sides and 1 edge leaving the lengths original as the were fairly all much the same length. Next set about cutting 2 biscuits per piece for preparation to assembly and glue up Assembly Inserted the No 10 biscuits and Titebond III glue. Brought out my trusty Backline clamps, (knowing clamps are the flavour of the month here on Craftisian) Set everything up on the garage floor as the are big boys ( being bigger than LBD'S (snicker snicker) and not having anywhere else to work it was turning Japanese for a while. BTW the picture is not sideways that's natural. Once the glue was set it was squaring time, now this may have been an oversight on my behalf as I could have used a straight edge and aligned the all before clamping, looking closely you can see there is an irregular edge on both sides. I was no real big deal as I used a "Calibrated" wedge some frog tape and a straight edge to trim them on each edge. See picture No 3 in the top section. Scroll up! Plugging and filling. You may have noticed a series of stains and nail hole visible, to remove these the following process were employed. 1. Oxalic Acid on the nail stain holes 2. Tooth picks (shriek size) were driven into the holes 3. potholes and defects filled with Timbermate Edge fitment Now out of the Backline clamps the boards exhibited a similar effect to a chinese wooden dragon and to increase the depth of the shelf I added an edge strip. Its now day 2. The shelf space is about 1010 mm wide so I cut the shelf to length and did some surface finishing. Note the absence of most of the stains and nail holes from what looked like a recycled rustic timber shelf Sanding and sealing yep did a bit of sanding started at 40 g and finished at 320 g, rounded the top edge with a trimmer and sanded everying again. It all looked good so I sealed it. Thats sealer on the cardboard BTW. Day 3 Fitted the shelf and admired my time wasting activity!
Can't argue with extra shelf space, but for me the large amount of wood consumed is a bummer. Me like that you used short stock and made it all work, plus you have some nice stuff that the LBD might not possess!
