LRyIrue LnuINATEI USS CoruSrIruTION SNIM I ... - Wood Tools

26
Swing-IJp Shelf Construction View
OVERALL SIZE: 24"W x 60"1 x 32"H
FronVBack edging
3/q" x1lz" x60"
\S
continuous hinge, -._E
60" lons
ECA?|
I
Wall frame stile
3/r" x3" x12"
Shelf
3/q" x23Ya" x591/q"
Wall frame rail
3/q"x3"x60"
' Support arm
3/a" x143/a" x113/q"
upper half-lap cutout is on the front
face. This joinery arrangement
counteracts the force of the fully
loaded shelf pulling on the frame.
Rip your rails and stiles to width
and cut them to length. Then
clamp a stop block to an extension
on your miter gauge, and set up a
:J/+"
dado blade to cut the half-laps
(Figure 1). But before cutting
your frame material, I suggest you
make test cuts in scrao wood of
the same thickness.
After cutting the halfJaps, spread
glue on the joints and assernble the
frame. Make sure the frarne is
square before drilling pilot holes
and driving two #6, s/s" screws
through the back of each joint.
Use a 3/+" dado blade to cut half-laps in the
fnme nils and stiles, Clamp a stop block to
an extension screwed to your miter gauge.
Workbench I December 1997
1Yz"-wide
continuous
hinge, 12" long
End edging
3/q"
x112" x24"
/"/
! t
Stop block
1%" x1/2" x4"
Support Arms
Begin making the support arms by
cutting a ply.woocl rectangle for
each arm and laying out the 35'
angled edge (Support Arm
Detail). Then cut the angles on
your table saw Again, use a long
miter gauge extension and stop
block to hold the pieces securely
during the cuts (Figure 2).
Solid woocl banding on the forward-facing
edges the support arms
neatly conceals the edges ofthe plywood.
Rip the banding from solid
stock ancl glue it to the plywood. I
found using clamps on the angled
edges was awkward, so instead I
used electrical tape, which stretches
enough to pull the banding snug.
Use a long extension and stop block to
hold the support arms securely. Set your
miter gauge to cut the edge at a 35" angle,
What You'll Need
Lumber
8 bd. ft. of rrl4rr birch
1 4x8 sheet. of3/+rrpl)ryvood
Hardware
t ir. 1tl2rr-wide continuous hinge
(8) #6" 5/s" flat-head screws
(60) #4 * 1/zrr flat-head screws
(12) #10, 3rr flat-head screws
10 sq, ft. plastic laminate
Support Arm Detail
A
l'13/4"
V >23/q" <
Following the gluing sequence I
used will minirrize the number of
seams that show (Figure 3).
Mochining fhe Sfop Blocks
To properly position the support
arms, I n'rade two stop blocks and
rnountecl thern to the unclersicle of
the shelf. The notch in each block
fits over the support ann, ancl the
anglecl encl helps ease the arm into
position (Stop Block Detail).
For safety, I machinecl the small
blocks as one piece. Glue two
:r/.r"-thick pieces together to make
a 1r,/,rr-thick blank. Then rip the
blank to 1llsil wide and crosscut it
Glue banding to the bottom edge of the
arms first, then to the angled edge, and
to the front edge last to cover the joints.