Corner Shelf

This will be a storage/display shelf...it will be above two doors in the corner.

 

Design

Wood Selection, Milling Wood

Assembly

Sanding, Finish Application

Hanging the Final Product

 

Design

This shelf will hold numerous Lego items.

Silas and I measured all of his Lego creations and determined that most of them would fit on this shelf.

The corner design is to utilize some dead space in his room.

My first Sketchup of my design...

Wood Selection, Milling and Assembley

 

 

I purchased some 4/4 poplar stock from Larry at Heartwood in Star, MS.

Boards were 7+ inches wide and 10 feet long.

They surface planed both sides of the boards to 7/8 inch thick and jointed an edge.

Cindy and I cut the boards into 6 foot and 4 foot sections in the garage...

In the shop, further rough milling was done at the MFT3 table and the P66...
Rough blanks were then stored for a rest...then will be planed down to 3/4...
After planing to 3/4 inch the back boards were ready for joinery milling...they were grooved at the P66 using a dado head.
The shelf boards had been milled a skosh fat...to make them fit a rebate was thinned with a skew rabbit plane...
The corners were mitered...board was wide enough that the miter cut did not go through...
...finished the cut with a carcase saw.
Mortises for the floating tenon at the miter joint were made at 45° with Domino machine.
End view of mortises and dado.
With floating tenons dry fit...
...it is doubtful that I will be able to use these at install...though there will be no glue on this joint at install the angle will probably not allow insertions...the use of the floating tenons was more about dry fit at the shop.
Dry fit of the two shelves...
... the front edge attachment...glued and nailed...

The end caps...laid them out, cut the 45° on chop saw...would not quite go all the way...then reversed it and chopped square...

End cap was put in place with glue and brads...
Sanding, Finish Application
Prior toassembly, surfaces were sanded with Rotex 150mm with a grit progression of 120x-220x-400x...
...I padded on a coat of amber shellac.
Hanging the Final Product
We hung the shelves one at a time...the Domino tenons were not able to be used due to the tight space at the angle in the corner...the shelves were screwed into studs with #8 x 2 inch screws.
Silas did a test fit with some of his Lego items...

Fit well...

 

 

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