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32 shelves, 4 notches per shelf

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Forum topic by cowboyj posted 08-21-2010 06:46 AM 2495 views 0 times favorited 4 replies Add to Favorites Watch
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cowboyj

9 posts in 2382 days


08-21-2010 06:46 AM

I am building a wall-sized, bookcase-style, system of shelves. The shelves will be birch veneered plywood purchased from my local BB. The supports for the shelves are a surface-mounted system, about 5/8 inch wide by 3/16 inch deep. To accommodate the surface-mount, I will need to make 2 notches in the sides of each shelf, for a total of 4 notches per shelf. I will have 32 shelves, requiring 128 notches.

In addition to having the notches accurately located, I want to eliminate (or at least minimize) chip-out from the plywood veneer. Since I will be making 128 notches, I would like the procedure to be as efficient as possible. How would you do this?

I have considered cutting the notches on my table saw with a dado cutter after using a template to guide making chisel cuts on the back side of the shelf to minimize chip-out. I have also considered using a template to guide a small diameter, down-cutting router bit, cutting a little over half of the depth, from each side.

Do you have any suggestions?

-- Jerry


4 replies so far

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ChefHDAN

809 posts in 2317 days


#1 posted 08-21-2010 12:49 PM

I would;
1) clamp them all together with a sacrifical piece on the top and bottom
2) set a fence across end
3) use router with straight or spiral bit
4) cut each Dado in all boards at once
5) reset fence and repeat

This will give ZERO chip out and the groove will be exactly the same for each board in each location providing you correctly mark each board and don’t do my usual goof and start flippin’ them around befor you remember to mark them.

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

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gmal1

6 posts in 2467 days


#2 posted 08-25-2010 04:22 PM

Just an addendum to CessnaPilotBarry’s comment; there are special shelf supports you get that are made for the dado; only require a 1/4 inch dado in the sides.

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cowboyj

9 posts in 2382 days


#3 posted 08-26-2010 05:13 AM

Thanks for the replies above. This is a GREAT forum. The absence of spam, flaming, and off-topic posts I assume should be credited to a moderator(s), so thank you, moderators.

gma1 Good suggestion. I got my shelf supports from McMaster-Carr, I think they were called shelving standards. They have a 3/16” depth.

CessnaPilotBarry Your comments describe the way I originally designed my project. However, my 3/4” plywood from the big box store was actually 11/16”. Given that my dadoes were 3/16” deep, this left an area that was 5/16” thick between the bottom of the dadoes without an offset. Even after I looked at offsetting the dadoes, I was not comfortable with the trade-off of increasing the amount of offset without removing too much support from the front edge of one side of the shelf. Too conservative, perhaps.

ChefHDAN I decided to follow your suggestion. My 32 shelves were grouped into 3 different sizes, so I had 3 setups to go through. Here is a picture of my setup for the longer shelves:

http://www.flickr.com/photos/ohiookie/4927875671/

And here is a picture of the result. I have not examined each shelf individually, but this was an outside shelf in the setup, and I see no chip-out in the veneer surface.

http://www.flickr.com/photos/ohiookie/4927875779/

Thanks for the suggestion!

-- Jerry

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ChefHDAN

809 posts in 2317 days


#4 posted 08-27-2010 01:31 AM

Wow Cowboy very jealous of your shop space nice cabinetry

-- I've decided 1 mistake is really 2 opportunities to learn.. learn how to fix it... and learn how to not repeat it

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