2007_sliding_bookrack.pdf

WOODWORKS: INTERMEDIATE PROJECT 2007-2008

SLIDING BOOKRACK

The design of this ingenious book holder was inspired by the work of Greene & Greene, two architects who designed Arts & Crafts homes and

furnishings in the early 20th century. Their detailing was exquisite yet they were also quite practical, as with this bookrack, which works simply

on friction. The bookends slide on two rails to keep any number of books upright.

In this intermediate-level project you’ll be cutting and shaping with a band saw, router, table saw and other tools to create a machine-perfect piece.

And when it’s all done, you’ll learn more about applying and using stains and finishes to protect the wood and keep it looking beautiful.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2007-2008 SLIDING BOOKRACK

TOOLS REQUIRED

SHOPPING LIST

Recommended wood: Oak

Alternate wood: Pine

Hand Tools

– Mallet

– Screwdriver

Power Tools

– Random-orbit sander

– Router

– Router table with rabbeting bit

– Table saw with dado set

– Band saw or scroll saw

– Mortising machine

– Power planer

Miscellaneous

– Pencil

– Tape measure

– Double-stick tape

– Safety glasses

– Carpenter's glue

– 120-, 150- and 220-grit sandpaper

– Clean, lint-free cloths

– Respirator

– Gloves for finishing

– Mineral spirits (for oil-based stains

and finishes)

– Water-filled metal container with

tight-fitting lid (for oil-based stains

and finishes)

– Minwax ® Wood Finish ™ Stain Brush

or other good quality, natural-bristle

brush (for oil-based stains and

finishes)

1' x 8' oak:

3 lin. ft.

Walnut:

Scrap

#8 x 1-1/2" flat-head screws

CUTTING LIST

Overall Dimensions: 7-13/16"h x 6-1/8"w x 23-1/2"l

Key Part

Pcs. Dimensions

Bookend

3/4" x 5-1/2" x 7"

Endcap

3/4" x 2-1/8" x 6-1/8"

Base

3/4" x 5-3/4" x 1-1/4"

Rail

3/4" x 15/16" x 23"

Pegs, Walnut

3/8" x 3/8" x 1/4"

WOOD FINISHING PRODUCTS

Recommended Finish

Prep:

Minwax ® Pre-Stain Wood Conditioner

Alternate Finish

Prep: Minwax ® Pre-Stain Wood Conditioner

Stain: Minwax ® Gel Stain Aged Oak

Finish: Minwax ® Fast-Drying Polyurethane semi-gloss

Wax:

Stain/

Finish: Minwax ® Polyshades ® Bombay Mahogany

Optional

added

finish:

Minwax ® Paste Finishing Wax

Minwax ® Fast-Drying Polyurethane or

Minwax ® Wipe-On Poly

Wax:

Minwax ® Paste Finishing Wax

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2007-2008 SLIDING BOOKRACK

BEFORE YOU BEGIN

Good craftsmanship begins and ends with good work habits, so make

the following steps part of your routine workshop practice. If you have

any doubts or questions about how to proceed with a project, always

discuss them with your shop instructor.

• Carefully and fully review plans and instructions before putting a

tool to the project lumber.

• Work sensibly and safely. Wear safety goggles when doing work that

creates flying chips and sawdust; wear the appropriate respirator

whenever making sawdust or working with thinners or other solvents.

• At the end of every work session, clean up your shop area and put

away all portable tools.

12. Predrill the bases and bookends. Screw these parts together on the

rail and endcap assembly and test their fit. There should be a little play

so the bookends will slide. Disassemble the bases and bookends for

finishing.

13. Sand with 180- and 220-grit sandpaper to gently round the edges

of the bookends, endcaps, rails and bases. Don't sand the bookends'

bottom edges. Proceed to the staining and finishing.

14. After the finishing is done, screw the bases to the bookends and

load in your books.

STAINING AND FINISHING

Woodworker’s Tip: Though you may be tempted to cut short

your sanding, preparation and application time, don't do it. These

tasks are very important steps in obtaining a high-quality finish.

Remember, it is the finish, just as much as the fit and smoothness

of the parts that will have great bearing on how people judge your

craftsmanship. To ensure an excellent result, follow the steps

listed in this section and also the instructions the finish manu-

facturer puts on its products.

CUTTING AND ASSEMBLY

PROCEDURE

Make the Parts

1. Cut the bookends (A), endcaps (B) and bases (C) to their final size.

Cut the rails (D) an extra 1/8" thick. You can cut paired pieces at the

same time by holding them together with double-stick tape.

2. Cut the shapes of the bookends, endcaps and bases on the band saw

(Fig. 1). Sand the sawn edges progressively using 100-, 120- and 150-

grit sandpaper.

FINISHING TIPS

• Test the stains and finishes you are planning to use on scraps of

wood. On the back of the scrap, mark the stain/finish combination

and the type of wood. Allow all samples to dry thoroughly before

making your final finish selection. Save your samples for quick

reference on future projects.

• All stains and finishes must be allowed to dry thoroughly between

coats. Remember that drying times can vary due to humidity and

other climatic conditions.

• If you have some leftover stain or finish, wipe the can rim so that

stain or finish in the rim won't dry out and prevent the lid from

forming a tight seal.

• Brushes used for oil-based products, such as Minwax ®

Polyshades ® or Minwax ® Fast-Drying Polyrethane must be

cleaned with mineral spirits.

3. Rout the bookend profile with a 3/8" rabbeting bit (Figs. 2 and 5).

Raise the bit in 1/16" increments to avoid tear-out. Use a chisel to

square the rabbet's inside corners. To safely begin the cut, pivot the

work piece against a starting pin. Once started, you can ride on

the bit's bearing.

4. Cut shallow mortises into the bookends using a mortising machine

(Fig. 2). Cut through mortises in the endcaps and rails (Figs. 3 and 4).

Some tear-out on the back is inevitable, even with a sacrificial board

under the rail, but you'll remove it in the next step.

5. Plane the rails to their final thickness using a power planer. Place

the torn-out sides facing up; they'll come out perfectly smooth.

6. Cut tenons on the rails using a dado set (Fig. 4).

15. Dust off the piece and wipe it carefully with a clean, lint-free cloth

lightly dampened with mineral spirits.

7. Make the walnut pegs (E) from 3/8"-thick square blank. Cut the

pegs to length with a band saw, Japanese pull saw or dovetail saw.

Recommended Finish

16. Apply Minwax ® Polyshades ® following the directions on the

can. Use a good quality, natural-bristle brush suitable for use with

polyurethane. Stir the can contents thoroughly before starting and

periodically repeat stirring during your work session. Allow the first

coat to dry overnight.

Assemble the Bookrack

8. Glue and clamp the rails and endcaps. Work on a flat surface.

Check the assembly for wobble before you set it aside to dry.

9. Glue pegs (E) into the bookends and endcaps. Leave the

pegs proud by at least 1/16". Scrape excess glue from around

the pegs before it dries.

17. The next day, sand all surfaces lightly with 220-grit sandpaper or

very fine (000) steel wool using with-the-grain strokes. Dust off and

wipe all surfaces with a cloth dampened with mineral spirits. Apply a

second coat of Polyshades ® and set the rack aside to cure overnight.

To achieve a deeper color, you may apply a third coat after 4-6 hours,

repeating the application directions. Allow the project to cure for

several days before using it.

10. After the glue is dry, round over the pegs' sharp corners with

180-grit sandpaper in a random-orbit sander.

11. Mark the positions of the bookend slots directly from the rail

and endcap assembly. Cut the slots using your miter gauge and a tall

auxiliary fence (Fig. 6). Make multiple passes, raising the blade 1/4"

with each cut.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2007-2008 SLIDING BOOKRACK

18. After the finish is dry, apply a coat of Minwax ® Paste Finishing Wax

over every surface and rub it out with #0000 steel wool to an even

sheen. This is an essential step. The wax lubricates the rails, allowing

the bookends to slide smoothly.

DANGER: Rags, steel wool, other waste soaked with oil-based stains

and clear finishes, and sanding residue may spontaneously catch fire if

improperly discarded. Immediately place rags, steel wool, other waste

soaked with this product, and sanding residue in a sealed, water-filled

metal container. Dispose of in accordance with local fire regulations.

Woodworker’s Tip: If you achieve the desired color on the first

or second coats of Polyshades ® , apply a clear coat of Minwax ®

Fast-Drying Polyurethane or Minwax ® Wipe-On Poly for added

protection.

When using oil-based wood finishing products:

CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS.

Contents are COMBUSTIBLE . Keep away from heat and open flame.

VAPOR HARMFUL . Use only with adequate ventilation. To avoid over-

exposure, open windows and doors or use other means to ensure fresh

air entry during application and drying. If you experience eye watering,

headaches, or dizziness, increase fresh air, or wear respiratory protec-

tion (NIOSH approved), or leave the area. Avoid contact with eyes and

skin. Wash hands after using. Keep container closed when not in use.

Do not transfer contents to other containers for storage.

Alternate Finish

19. Apply the Minwax ® Gel Stain you've chosen using a clean, lint-free

cloth or natural-bristle brush. Allow the Gel Stain to set for about

3 minutes, then wipe off any excess with a clean, lint-free cloth. To

achieve a deeper color, you may apply a second coat after 8 to 10 hours,

repeating the application directions for the first coat. Allow the stain to

dry for 24 hours before applying the finish.

FIRST AID: In case of eye contact, flush thoroughly with large

amounts of water for 15 minutes and get medical attention. For skin

contact, wash thoroughly with soap and water. In case of respiratory

difficulty, provide fresh air and call physician. If swallowed, call Poison

Control Center, hospital emergency room, or physician immediately.

Woodworker’s Tip: When wiping off stain, make certain that

your last wipe with the cloth goes with the grain of the wood. This

way, any stain you might miss during wipe-off will be visually

minimized by the wood grain.

20. Apply Minwax ® Fast-Drying Polyurethane following the directions

on the can. Use a good quality, natural-bristle brush. Allow the first coat

to dry overnight.

DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.

Contains solvents which can cause permanent brain and nervous

system damage. Intentional misuse by deliberately concentrating

and inhaling contents may be harmful or fatal.

21. The next day, sand all surfaces lightly with 220-grit or finer sandpa-

per using with-the-grain strokes. Dust off and wipe all surfaces with a

cloth lightly dampened with mineral spirits. Apply a second coat of

polyurethane and set the piece aside to cure overnight.

WARNING: This product contains a chemical known to the

State of California to cause cancer and birth defects or other

reproductive harm.

DO NOT TAKE INTERNALLY. KEEP OUT OF REACH OF CHILDREN.

CONFORMS TO ASTM D-4326. Contact a physician for more health

information.

22. The following day, sand all surfaces lightly with 220-grit sandpaper.

Dust off and wipe the piece with a cloth lightly dampened with mineral

spirits and apply the third and final coat of polyurethane.

23. After the finish is dry, apply a coat of Minwax ® Paste Finishing Wax

over every surface and rub it out with #0000 steel wool to an even

sheen. This is an essential step. The wax lubricates the rails, allowing

the bookends to slide smoothly.

PRODUCT SAFETY

For your safety and the safety of those you work with, always read the

safety warnings, which manufacturers print on their labels, and follow

them to the letter.

WARNING! Removal of old paint by sanding, scraping or other means

may generate dust or fumes that contain lead. Exposure to lead dust or

fumes may cause brain damage or other adverse health effects, espe-

cially in children or pregnant women. Controlling exposure to lead or

other hazardous substances requires the use of proper protective

equipment, such as properly fitted respirator (NIOSH approved) and

proper containment and cleanup. For more information, call the

National Lead Information Center at 1-800-424-LEAD (in U.S.) or

contact your local health authority.

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CONTINUED - WOODWORKS: INTERMEDIATE PROJECT 2007-2008 SLIDING BOOKRACK

FIG 1. BOOKRACK DETAILS

#8 x 1 1 / 2 " Screw

This project was adapted with permission from American

Woodworker ® magazine, AW Media LLC, an affiliate of New Track

Media LLC, Suite 180, 1285 Corporate Center Drive, Eagan, MN

call toll-free: 1-800-666-3111.

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