So, what's the best way to assemble this thing? - Router Forums
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post #1 of 32 (permalink) Old 04-08-2010, 07:15 PM Thread Starter
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Default So, what's the best way to assemble this thing?

Hey! So this is my first woodworking project. It's a DVD shelf. I'm finished all of my cuts and routing, so I just have to sand, then assemble. Here's my issue...

I only have 2 bar clamps. Actually I only have 2 Pony 3/4" clamps...still have to get the bars.

The stand is 57 1/4" tall and 40" wide.

What's the best way to assemble this? The first picture shows the top and bottom where I have a 1/4" dado for the sides to be inserted. The sides also have 1/4" dados for the shelves as in pic 2. Pic 3 shows the rabbet for the back. Pic 4 is a shelf that I 'fixed'. My guide slipped while I was trimming the shelf, so I glued a piece of wood on and flush trimmed it. It's on the back, so I'm not worried about the gap...just glad I could fix it.

I noticed the side pieces are bowed a little...so I'm thinking that maybe I should put together the middle shelf first, wait for the glue to dry....then start assembling the sides to the top. Should I do one side at a time since I only have 2 clamps(One clamp on the top and one on the bottom?). Or should I get the 'carcass' glued together, then worry about the shelves and clamp out the bow?

Any help is appreciated. I'm a total noob and already went over my tool budget so be nice
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post #2 of 32 (permalink) Old 04-08-2010, 07:17 PM Thread Starter
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Edit:: Pic 3 above is the shelves and kick plate
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post #3 of 32 (permalink) Old 04-08-2010, 08:33 PM
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Put the table saw fence to the middle, clamp a 2x4 to the outside of the extension wing perpendicular to the fence. Glue the dados and use the fence and 2x4 to clamp them together. Put plastic sheet down to keep the glue off the TS surface.

Next, get more clamps. You never have too many.

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post #4 of 32 (permalink) Old 04-08-2010, 08:51 PM Thread Starter
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Oh, I don't have a table saw
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post #5 of 32 (permalink) Old 04-08-2010, 10:32 PM
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Don't know where you're from but there must be a place there to pick up a few clamps and do it the best way to show off the excellent job you've done so far. You can never have too many clamps.

Looks to me you are in the garage, making sure all is square and such, glue it all up and, keeping things square, park your car on it!!---just kidding, but get a couple heavy boxes you can put on it. Just keep the ends perpendicular to the rest and it should end up square. If you try it and it doesn't work just tell folks some idiot on the form is to blame!! BTW I want to say your work up to this point is very well done, preserve it!!

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post #6 of 32 (permalink) Old 04-08-2010, 11:59 PM Thread Starter
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Thanks for the compliments. This is my first time using a router(purchases a Hitachi M12VC Fixed/Plunge combo). Unfortunately I'm stuck with the circular saw for rips and cross cuts for now. But as long as I take my time it's ok.

I really hate my circular saw though. The motor is so low that I can't clamp any guide on that side. So I have to use the other side of the base which is really narrow. Tough to keep it level when ripping edges.

Anyways, it's been a great learning experience so far. I learned about tearout, how not to put your face where the router is shooting sawdust, and how to properly clamp a guide for the saw, haha. But I got to use a few router bits and I did a lot of test pieces before settling on the trim(the wife pocked that one). I was going to do a roman ogee but my bit os too small and it didn't look right.

I also stupidly made it a bit too wide for the space it's going in. I'm contemplating cutting 3/4" off of each side of the base and top. I mispoke earlier. It's a total of 45" wide, with 2" overhang for the top and bottom all the way around. I'm just scared of totally messing it up now that I'm almost dine.
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post #7 of 32 (permalink) Old 04-09-2010, 01:03 AM
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Been there done that, Ben... Now is the time to carefully think it all through.. draw a few sketches if it helps. You know, the old "measure twice, cut once" thing

Check out that new high-tech cordless router.. wireless and no recharging required!!
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post #8 of 32 (permalink) Old 04-09-2010, 10:16 AM Thread Starter
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I thought it was 'cut twice' so you get to use your tools more. HAHA
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post #9 of 32 (permalink) Old 04-09-2010, 02:51 PM
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Ben...

do you have any left over 1x's that are at least as wide as you unit?
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post #10 of 32 (permalink) Old 04-15-2010, 10:10 AM Thread Starter
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Hey! Yes I do have some 1xs. I realized I will be able to use one clamp on each side and just put some boards/2x4s on the top and bottom to equalize the pressure.

I think I'm going assemble the middle 1 or 2 shelves and sides, before putting the top and bottom on. For some reason I just feel like I am going to bow the crap out of it if I try to put the top/bottom together with no shelves holding the sides in place.

Anyway..progress so far...I'm sanding. Almost done with 100 grit. Then I'll move on to 150, then 220. I've decided to stain it with Ebony stain... I will probably use the Minwax pretreat on it too.

Why didn't someone tell me that using a sanding block would make sanding easier and more efficient? Why did someone tell me that good dust extraction would make sanding easier and more efficient? O wait, everyone did, but I was too dumb to realize it until i sanded a few boards

EDIT:: I did end up cutting 3/4" off of each side of the top and bottom and re-routed. So now it fits nice and snug where I wanted it to go!
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