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Подпись:Adding shelves to a carcase is one way to turn a simple wood box into a useful piece of furniture. The simplest method for installing shelves is to bore two parallel rows of holes in the side panels of the carcase and insert com­mercially available plastic or metal shelf supports. The two alternatives shown in this chapter require a little more prepa­ration, but they have a payoff in that there are no visible shelf supports to mar the appearance of the finished piece. Like commercial shelf hardware, hidden sup­ports (below and page 42) are adjustable; the difference is that they rely on nar­row wood strips recessed in rabbets cut into the underside of the shelves, and this makes them all but invisible.

For fixed shelves (page 43), you have to rout dadoes on carcase sides. The shelves are then glued permanently in place when the carcase is assembled.

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Подпись: 1 Making and installing the shelf supports Bore holes for the shelf supports using a commercial jig. After the carcase is assem-bled, make two supports per shelf. For each of them, cut a thin strip of wood about 1 inch longer than the gap between the rows of holes; make the strip wide enough to hold a dowel at each end. To mark positions for the dowels, insert a dowel center into each of two parallel holes, then press the wood strip against the points. Use the indentations for the dowel centers as starting points for boring the holes. Make the holes in the shelf- support pieces the same depth as the holes in the side panels. Glue dowels into the shelf supports, and when the adhesive has dried, install them on the side panels at the height that you want the shelf to rest.

HIDDEN ADJUSTABLE SHELF SUPPORTS

SHELVING2 Making and preparing the shelving

Подпись: 3 Installing the shelving With the shelf supports at the desired height on the side panels, test-fit the shelf in the carcase (above). Use a chisel to adjust the length, width or depth of the stopped rabbets, if necessary, to ensure a perfect fit that completely hides the shelf supports.

Use solid lumber, plywood or edge-glued boards (page 20) to make the shelving. Cut each shelf to the same width as the carcase panels and to a length equal to the distance between the side panels. Add edge banding to the visible edge of the shelf (page 39), if desired. To con­ceal the supports, rout stopped rabbets in the shelf. Start by positioning the shelf on the sup­ports and outlining their locations on the under­side of the shelf. Using a wood pad to prevent any marring, clamp the shelf to a work surface. Fit a router with a rabbeting bit, then set the depth of cut to the width of the shelf supports. Gripping the tool firmly with both hands and rest­ing its base plate on the shelf, rout each rabbet (above), making as many passes as necessary to cut to the marked outline. Square the ends of the rabbets using a chisel (page 38).

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FIXED SHELVING

 

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Подпись: WeatherboardПодпись: 2 Making and dry-fitting the shelving Use solid lumber, plywood or edge-glued boards (page 20) to make the shelving. Cut each shelf to the same width as the carcase panels and to a length equal to the distance between the side panels plus the depth of the dadoes. Add edge banding to the visible edge of the shelf (page 39), if desired. To check the fit of the shelving, join the top and bottom panels of the carcase with one side panel, then fit the shelving into the dado (right). Fit the other side panel on top. Adjust the length or width of the shelving, if necessary, to ensure a perfect fit.
SHELVINGSHELVING1 Preparing the carcase side panels

Set the side panels one on top of the other on a work sur­face, edges and ends aligned, and mark cutting lines for the dadoes on the leading edges of both panels. Make the width of the dadoes equal to the thickness of the shelf; the depth should be one-half the thickness of the side panels. Install a dado head on a table saw and align the cutting lines on one side panel with it. Crank the blades to the proper height for the depth of cut, then position the rip fence flush against the panel. Cut a test dado in a scrap board and adjust the width of cut if necessary. Clamp a featherboard to the fence above the dado head for added stability. To make the cut in each panel, turn on the saw and feed the panel into the dado head using the miter gauge and both hands (left). (Caution: Blade guard removed for clarity.)

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Gluing up the carcase

Apply a thin glue bead into the dadoes in the side panels and on the contacting surfaces of the shelving while gluing up the carcase. Spread the glue evenly and then assemble the box as when dry-fitting (step 2). Clamp the corners of the carcase for dovetail joints (page 32) or for rabbet or plate joints (page 35). For the shelving, install a bar clamp across each edge of the shelf, protecting the side panels with wood pads; place a VTinch-thick wood chip under each pad to focus some of the clamping pressure midway between the edges of the shelving. Tighten each clamp a little at a time until a thin glue bead squeezes out of each dado.

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