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Woodworking blog entries tagged with 'plywood'

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Castle Bookcase #11: Gluing the Turrets

329 days ago by RaggedKerf | 0 comments »

Today I finished the lower part of the turrets. The bottom pieces were glued up this morning. Then when they were dry (enough) I attached them to the turrets: Then I did a test fit a few hours later and here is what it looks like: Looking good, so I moved on to glue up the corbels and main turret platform like so: As everything dried I cut out two 9” diameter circles from the 1/2” plywood for the tops of the two turrets. More fun with the scrollsaw! ...

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Castle Bookcase #10: Modifying the Turrets

329 days ago by RaggedKerf | 0 comments »

I took the opportunity today to cut doorways in the sides of the turrets per Sara’s suggestion. With the razor saw and a box cutter it was not difficult. I sketched out two Medieval looking arch doorways and cut them out. Once the turrets were finalized, I grabbed the scrap 1/8” hardboard (leftover from the back I cut out a while back) and used the scrollsaw to cut out two semi-circles to make “ceilings” for the little turret rooms. Here’s the glue-up in pr...

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Castle Bookcase #9: We Got Turrets!

329 days ago by RaggedKerf | 0 comments »

This is a short post but has a picture that shows more than I can write. I cut the sonotube up in two 12” long segments (the sonotube, used for pouring concrete pillars, is 8” in diameter and made of a heavy duty wax lined cardboard—-in short the Japanese saw cut through it like butter!). On those two sections (the kids got the 4’ of scrap to play with lol) I cut out a semi-circle, leaving half the tube open for 7”. That left a 5” tall tube trailed by 7...

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Castle Bookcase #8: First Tower

329 days ago by RaggedKerf | 0 comments »

I spent the time I had today out in the muggy shop sweatin’ and sandin’. I took the little palm sander to all the front edges of the plywood shelves and rounded everything over. Lesson learned: next time sand everything BEFORE you assemble…. I had decided over the weekend to forfoe adding trim to the front of each shelf because this thing will be primed and painted anyway…you won’t be able to tell what type of wood was used to begin with. Once all the crack...

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Castle Bookcase #7: Decorations

329 days ago by RaggedKerf | 0 comments »

After discussing it with my wife, we decided it would be better to have another shelf on the bookcase and shorten the toy storage area. Easy enough. I ripped out a new shelf, trimmed to size a d drilled pocket holes. Some glue and screws and a other shelf is born. Hint: it’s the narrow one directly above the large opening, bottom left of the picture below. Then I cut out the toy storage front piece with the jigsaw: When it was free, I used the tracing paper outline of a flowe...

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Castle Bookcase #6: Trim Part II

329 days ago by RaggedKerf | 0 comments »

I used what time I had today to make the final cuts on the base moulding and attach both sides and front with glue and nails. Used up quite a bit of time just clearing space in the garage and setting up an assembly table with sawhorses and of course cleaning up and putting things away so my wife could park her car later. That’s when it dawned on me: this is the largest project I’ve attempted since the workbench! Anyway, after fiddling with the moulding, I decided on pl...

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Castle Bookcase #5: Trim

329 days ago by RaggedKerf | 0 comments »

Today was a short day in the shop. I had to split my time between the bookcase and weeding, trimming some bushes and planted a rosebush. The sun finally broke through the clouds and the rain we’ve been socked with for the past week so I couldn’t pass up the opportunity to get some yardwork done during naptime. That said, I did accomplish something today: I fired up the new router table for the first trial run and it was an unqualified success! Despite its humble appearance ...

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Castle Bookcase #4: Carcase Assembly Part II

329 days ago by RaggedKerf | 0 comments »

Today I installed a block (2 2×4 cut-offs glued and screwed together) to support the bottom shelf, directly under the support brace for the main shelf. Here it is before installation: It was a perfect fit and will carry any weight from the top shelf down through the bottom shelf nicely, I think. To install it, I drew lines where the vertical support will go, then countersunk screws in that space to hold the block. A layer of glue and the vertical support was installed with p...

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Castle Bookcase #3: Carcase Assembly

329 days ago by RaggedKerf | 0 comments »

Spent an hour in the shop today assembling the carcase. It was very quick. First I marked on the side where the bottom shelf and top shelf would be, drew layout lines and coated with glue. Then I put the shelf in place, tightened the Kreg screws and bam, shelves installed. I flipped the side with two shelves attached and repeated the process for the other side and voila, sides and shelves done! Love the pocket screws…perfect method for plywood. Then I repeated the steps fo...

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Castle Bookcase #2: First Cuts

329 days ago by RaggedKerf | 0 comments »

Today, I transferred all my measurements from the plans to the 1/2” ACX plywood (4’x4’ sheets) I bought last week. Whipped out the Versacut and sliced and diced till i had the sides, top, bottom shelf, main shelf inner support and toy front cut out. I also decided to lose the lop shelf and shrink the height from 42” to 36” to better fit the space i have to work with in Kylie’s room. Also decided to cut down the large book space (20” is way too b...

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