DVD-CD Storage Cabinet

When my mother-in-law asked me to design a DVD-CD storage cabinet, these plans are what I had originally come up with. It turns out she really only needed to store DVD?s, so the plans were scrapped and gave way to the DVD storage cabinet you?ll see elsewhere on the site.

I was bummed that she only wanted a simple shelf, because I had come up with a kinda clever way of locating the adjustable shelves to fit various combinations of CD?s and DVD?s. Although I never had a chance to actually build the original shelf, I'm publishing it here for those who might find it useful.
Material There isn?t much to say about materials. It?s designed with the same white melamine as the DVD cabinet, with white PVC edge banding. As with many of the projects you'll find here, it could also be built out of plywood or even solid lumber.

I did learn something new about edge banding while designing the DVD-CD storage cabinet and building the DVD shelf. Most of my experience with banding has been operating automatic glue pot edgebanders in a commercial shop. During my very first job in a cabinet shop I also had some exposure to a simple table-top hot air bander, but that?s about it.

Recently I bought a used Virutex hand-held hot air edgebander (apparently the same machine is marketed under the Grizzly brand name). I?m accustomed to high quality PVC edge banding and was quite disappointed to discover that virtually all of the pre-glued edge banding on the market is cheap, lightweight vinyl. No wonder hot air edge banding has such a poor reputation!

I contacted my favorite edge banding supplier, Frama-Tech, and they are able to pre-glue any of their stock PVC colors for a small fee. That?s pretty awesome considering they?re incredible at matching even the most obscure laminate color. Of course my first order of PVC was white for the DVD-CD storage cabinet but it could have been just about any color I wanted.

I?m used to 15/16? edge banding and it worked very well in the Virutex bander. Having a bit of extra width was helpful in making sure it completely covered the edge of the board when my hand wasn?t running very steady. I used a FastCap Quad Pro Trimmer on the edges and a Flush Cut Trimmer for the ends. It went very quickly and you can?t tell the difference between the hand-held bander?s work and that from a $25,000 automatic glue pot bander!

Hardware Other than some small size differences, the major difference between the original DVD-CD storage cabinet and the plain old DVD shelf is in the shelf pin hole location and hardware. Initially, I wanted the CD storage shelf to be configurable for several combinations of CD?s or DVD?s. Regular 32mm system holes don?t always line up nicely for storing items of a real specific size. So I placed holes in a modestly sized cabinet such that the resulting shelf spacing would be a ?perfect? fit for storing CD?s, DVD?s, or VHS cassettes.

In the original design I had figured on using a low profile, concealed shelf support. The main purpose for this was to allow the shelf to be centered on the pin holes rather than sitting above the holes on shelf pins. I also liked the clean look of no exposed shelf supports. This requires slot to be cut in the ends of the shelves to conceal the shelf support.

When I switched to the simple DVD shelf, I also simplified the construction by eliminating the concealed support in favor of an angled steel shelf support. The angled support didn?t require the extra groove in the ends of the shelves, but still centered the shelf on the pin holes. I left the concealed support in the original DVD-CD storage cabinet plans just so you could see a nice alternative method for supporting adjustable shelves.

Drawing File Even though the DVD shelf design turned out nice, I still like this design better. Hopefully you?ll enjoy it too. You can view the drawings by clicking on the link below. If you'd like to download a copy to your computer, right click then "save-as". Either way, you'll need the Adobe reader to view the file.

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Bookcase Plans

This set of free bookcase plans stems from a furniture project that went into my home office. My wife needed a bookshelf to store some of the kid's school things, but it needed to fit on a certain wall in the room. It also needed to be pretty tall to maximize the amount of storage space available.

As I was developing the bookshelf plans, I tried to make it simple to build. But I also wanted it to have a little more character than just a box with a bunch of 3/4" shelves in it. The result is now sitting in my office, packed full of stuff, and I think it fits the bill pretty well.
Size As I mentioned, the bookshelf needed to fit a certain wall in my office and be as large as possible. An overall width of 28" and height of 82" worked great.

Often, bookcase plans call for a depth of only 12". This seemed too small to me. I extended the depth to 14" to accommodate even the largest of books. The plans can be adjusted to nearly any size you like, as long as the shelves don't become too long to support their load without sagging.

Normally I suggest avoiding shelves that are more than 36" long. In this case however, you should be safe extending them to 48". The addition of a panel (or valance) along the front edge of the shelves serves to stiffen them. It also gives the bookshelf a bit more character than plain old 3/4" shelving.

Design A common practice with simple furniture designs, like bookcases and dressers, is to extend the wall ends to the floor. Then, a slightly recessed toekick is installed just below the bottom shelf, between the wall ends.

I like this look and it helps prevent the unit from tipping forward. So, I included it in the bookcase plans.

This bookcase could easily have been built as a simple box, much like a cabinet. But the recessed toekick gave me the idea to add the same detail to the top and to the adjustable shelves. You can leave off the valances, but they do add a nice detail without a lot of extra effort.

By adding the valances to the adjustable shelves, you also add a great deal of rigidity to the shelves. This allows you to build a bookcase with longer shelves and they won't sag under the heavy weight of books.

In this case, the extra strength is not needed. So the added valances are really just for looks.

Materials If you're at all familiar with any of my other plans, you won't be surprised to learn that I built the bookcase out of white Melamine. It's durable and easy to work with, but any 3/4" panel will work just fine.

If you choose a wood veneer plywood or particle board, the valance panels at the toekick, top, and adjustable shelves can be made from solid stock to match the veneer.

Something I discovered as I was assembling the bookcase was that I had failed to edge band the top edges of the wall ends. For an 82" tall bookcase it's not a big deal since you won't ever see that edge. If you shorten the bookcase plans so that the top is below eye level, then the top edges really should be finished.

Assembly I'm kind of in love with my Kreg jig, so that's what I used to assemble the bookcase. If you're not familiar with pocket hole joinery, I encourage you to check out these videos. They do a pretty good job of demonstrating the basics.

In this case, pocket hole screws are particularly useful for joining the valances to the top, shelves, and bottom. I also used them, along with Melamine glue, for attaching the top and bottom to the wall ends. An alternative would be to screw through the wall ends into the top and bottom, but I didn't want visible fasteners in the wall ends.

The "nailers" are sort of a throw back to cabinet construction that serve to help keep the unit straight and square. They're glued and screwed to the wall ends, top, and bottom.

Drawing File Overall, it's a pretty simple project. With the addition of the valances, and the right material, it will be equally at home in a casual office setting or the front room of your home.

Wherever you decide to put it, to view the plans just click on the link below. If you'd like to download a copy to your computer, right click then "save-as". Either way, you'll need the Adobe reader to view the file.

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Seeking more sustainable practices? Follow furnituremaker John Wiggers

June 22nd, 2011 in blogs         15 users recommend $(document).ready(function() {$("a.popit").fancybox();}); Photo: http://www.custommade.com/kidney-shaped-desk/by/John

John Wiggers is a pioneer of eco-conscious furniture. In 2005 John was commissioned by The Furniture Society to write a chapter on sustainability for their studio furniture journal: "Focus on Materials" (ISBN: 0967 100437). The materials used in his "Kidney Shaped Desk" can inform your own sustainable building practices...

How it started

It was a series of connections that led to the Kidney Shaped Desk's creation. From a gallery rep in Miami to a NY party featuring holistic-minded supermodel Christy Turlington (click hear to read more) and world famous designer Vladimir Kagan - never could I have imagined that one day I would be working with this icon to build some of his actual furniture.

My connection to Turlington and Kagan came through a common interest in holistic and sustainable living. After my unforgettable encounter in NY, I actively sought a means of incorporating an underlying mode of sustainability into my woodworking practices and into my surrounding environment. Diana Beresford-Kroeger's extensive knowledge of holistic healing and botany seemed to be the necessary key: the notion of introducing rare and unusual trees to the property surrounding my new woodshop seemed perfect. Diana helped develop a bioplan for what I was intending to create, and over time our discussions evolved into an ever expanding exchange of ideas.

The sustainable materials I used:

The Kidney Shaped desk emerged as I continued to wrestle with the idea of how to meld holistic Ayurvedic principles with sculptural furniture design. Using careful mathematics and sacred geometric proportions based on Feng Shui and Vastu Shastra principles, this desk was also designed to utilize discrete inlays of wood that were ultimately suited to their particular holistic attributes. These include special cuttings of Black Walnut for the drawer pulls, and woods such as Hawthorn and Sassafras inside the pencil drawer, all chosen for their natural holistic and aroma-therapeutic properties.

To finance a protype of the Kidney Shaped Desk desk, I needed a buyer. Fate smiled upon me when Todd Marckese needed a desk for clients with strong holistic beliefs. The design I had been tweaking for almost a year wound up meeting the clients' specifications perfectly. I faxed Todd the drawings and explained in detail the holistic attributes of the various woods I was intending to use as inlay.

Less-common sustainable woods:

The main structure was crafted from FSC certified ply, and laminated with Macassar Ebony veneer. The inset of black Tuscany leather was bordered with a radiating grain pattern of wood that was cut to allow it to cascade like a waterfall down the vertical sides of the apron. The plinths on the legs were satin stainless steel.

Inset into the back of the desk were 3 drawers crafted from solid cherry. These drawers were mounted to the Macassar drawer fronts by means of sliding dovetail construction.

Inside the pencil drawer was a pair of trays made of a wood called Sassafras (Sassafras albidum). Sassafras carries within it an oil based complex of compounds that are naturally saturated within the wood itself – both as a wax and as oil. The oils contained within the Sassafras are released as an aerosol each time the tray is opened and exposed to air.

Hawthorn, a traditional healing wood, makes up a small storage compartment between the trays. It was well known to the ancient Greek herbalists, and records indicate that it has been used in Ayurvedic medicine dating back almost 5,000 years.The benefits of the aroma-therapeutic properties of Hawthorn include stress alleviation and heart strengthening. According to Diana Beresford-Kroeger, Hawthorne promotes an overall feeling of well-being and clear thinking.

When you incorporate these kinds of woods into your projects, you give clients access to traditional holistic health benefits that derive from specially-chosen natural materials and a deeper connection to the environmental source that their furniture comes from.

Contributor John Wiggers is a CustomMade.com affiliate and a seminal voice in the field of green woodworking. Feel free to pose any questions relating to sustainability and eco-friendly woodworking practices below and John will address them.

Thinking about going pro and selling your woodwork? Or just want some advice on how to market your business and make it stand out in the marketplace? Well this blog’s for you.

A joint venture between Fine Woodworking and CustomMade, The Pro Shop will give you tips on selling custom furniture or just getting started in the business.

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Adjustable, Collapsible, Stackable, Packable Lights

June 23rd, 2011 in blogs         2 users recommend $(document).ready(function() {$("a.popit").fancybox();});

Adjustable height lights.

Photo: John Tetreault

Last year my wife wanted a grow light to start her seedlings. Ideally it would be adjustable to keep the light close to the seedlings as they grow. This prevents the plants from getting "leggy" she said. 

I first bought the lights so I could design the stands around them. They happen to be GE 22 inch under cabinet fluorescent lights from the local big box store. The bulbs that came with them were 15 watts I think, but you could switch those out for special gardening bulbs if you wish.

I used small pieces of mahogany and redwood for the stands, which are both relatively water-friendly woods. The vertical pieces have three square mortises in each to allow for different heights of the horizontal pieces that hold the lights. The horizontal pieces have through tenons on each end and a square peg holds them in place. A single dovetail at the bottom of the vertical piece locks into the base.

Each year, my wife expands the garden and I've been adding more light stands. It turns out they stack rather nicely, all in a single box up in the attic, until the following spring.

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Doug’s Garage Shop in Kansas

From: Doug Heacock

Location: Lawrence, KS

Hobbyist or Pro: Hobbyist

Shop Type: Garage

Square Footage: 250-499

Shop Description:
I’ve been a woodworker for years (my dad has a nice shop), but recently decided to set up a shop of my own in my 12' x 24' garage, which I’m sharing with yard tools, bikes, and camping gear. So far I have a table saw and a planer, a few smaller hand-held power tools, and a few hand tools–it’s a good start (and there’s not a lot of space for much more). I like the window next to the workbench, and even though there’s no heat or A/C, I love to be in there.

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New Hot Rod Powered Drivers from DeWalt

June 24th, 2011 in blogs         7 users recommend $(document).ready(function() {$("a.popit").fancybox();}); Photo: courtesy of DeWalt

The cordless-tool power race has a bunch of new hot rods competing for pole position.  DeWalt just released news about a series of compact 20-volt lithium ion powered drills and drivers.  The 20-volt MAX Lithium Ion mighty-midget drill and drill-drivers combine big power in a manageable size.

First off, the line is a DCD780C2 Li-Ion Drill/ Driver that delivers power from a 1.5 Ah battery through a two-speed transmission offering 0-600 rpm for heavy driving and 0-2,000 rpm for efficient drilling. A 1/2in. keyless chuck keeps small bits centered without the inherent run-out of hex-collet bits. Combine this accuracy with a 15 position clutch and this little brute becomes adept at installing hinges and hardware that require high accuracy and a delicate touch.  

DeWalt paid careful attention to the weight balance of the motor and battery for a more comfortable, lighter feel. Combined with a well-shaped grip this drill should be very pleasant to use and the built-in LED light will bring accuracy to dark corners. The light has a 20-second delay after trigger release.

An included belt hook and bit holder can be mounted on either side of the drill for those who like to drive on the left side.

The drill will run about 220 bucks with two batteries, a fast charger, and a case.

Next up are the DCD780C2 and DCF885L2 1/4in. impact drivers.  These two are identical except for the battery ratings with the C2 running on 1.5 Ah and the L2 using a 3.0 Ah battery. 

A short  5.5 inch overall length, excluding the driver bit, and a svelte 2.8 pounds of weight make this little driver king of the long reach.  The drivers have a one-handed loading, 1/4-inch hex chuck that will accept 1-inch bit tips keeping that short overall length useful. These powerful little drivers produce 117 foot/pounds maximum torque and up to 3200 impacts per minute for serious driving power in a small compact frame.

An LED light, belt hook and bit holder add convenience.

The 1.5 Ah driver sells for around 220 bucks while the 3.0 Ah will run about 270 bucks. Both come with an extra battery, fast charger and a storage case.

A full size drill, rotary hammer, circle saw and reciprocating saw round out the 20-volt MAX Lithium Ion line-up.

Eight different kits ranging from a compact drill - driver combo to a complete assortment of the 20-volt MAX tools are available so you can pretty well custom tailor your setup to your needs without buying tools you won't often use.

Expect the DeWalt 20-volt MAX Lithium Ion tools to be available in September.

posted in: blogs, dewalt, cordless drills, drivers
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New: Don’t miss posts by contributing editor Roland (aka Rollie) Johnson. Over the year’s Rollie’s tested countless tools for the magazine. His fascination with motors and gears goes beyond woodworking, he's also an enthusiastic hot-rodder who likes to restore old cars, and is the author of Automotive Woodworking (Motor Books International, 2002).

Contact us: Keep us in the loop on tool news or ideas for this blog. Email the editors at fw at taunton.com or “tweet” Rollie via Twitter at https://twitter.com/Toolwriter.

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Free Festool Stuff = No-Brainer

I just wanted to bring your attention to a sweet giveaway opportunity from the folks at Festool. This month, they are giving away a Festool TS-55 Track Saw and a CT-26 Dust Extractor! Yeah I thought that might catch your interest. Simply head to FestoolSweepstakes.com and enter to win. Its a great way to get your hands on some excellent gear!

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