How to build a bookcase carcass on a Panel Saw

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Forum topic by TheRock posted 11-03-2014 01:39 PM 772 views 0 times favorited 2 replies Add to Favorites Watch
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17 posts in 1675 days

11-03-2014 01:39 PM

Topic tags/keywords: bookcase panelsaw bookcase instructional video

I made a new instructional video on how to build a bookcase. Part 1 only shows how to build the carcass. Nothing really special about the bookcase, but it has a couple of unusual construction techniques. The entire carcass is made on my DIY panel saw that is only 7 feet long (the fence is 8 feet).

First I rip a 4×8 sheet of oak plywood to 24.375” and crosscut it to about 7 feet long. Next, using the router on the panel saw, the dados are cut for the fixed shelves. Then I rip it in half to form both the left and the right hand sides of the shelves. The dados can’t help but match.

The dados for the back (1/4” oak plywood)are the cut with the saw in two passes. The blade is retracted so this dado will be the same depth as the other dados. The first pass is towards the back of each side. The second cut is on the front side of the dado. (Care must be taken to insure that the left and right sides are mirror images. Don’t want to cut the slot near the front on one of them.)

With the saw in position to cut the side of the dado nearest the front, we extend the blade so it will cut all the way through. At this position it is in the exact location to cut the fixed shelves to width, and that is what we do with the other half of the sheet of plywood.

Next we cut the fixed shelves to length, and glue the carcass together.

We also cut the other shelves and the back.

Part 2 will show the rest of the construction: Drilling the shelf pin holes, assembling the face frames, sanding, staining and varnishing.

Here is the video

-- TheRock

2 replies so far

View Fish22's profile


83 posts in 2532 days

#1 posted 11-03-2014 02:07 PM

That is a really impressive panel saw. The ability to mount the router is very unique.

-- Bryan, South River, NJ

View TheRock's profile


17 posts in 1675 days

#2 posted 11-03-2014 02:57 PM

Thanks! I put a lot into that puppy.

-- TheRock

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