• Hi all and welcome to TheWoodHaven2 brought into the 21st Century, kicking and screaming! We all have Alasdair to thank for the vast bulk of the heavy lifting to get us here, no more so than me because he's taken away a huge burden of responsibility from my shoulders and brought us to this new shiny home, with all your previous content (hopefully) still intact! Please peruse and feed back. There is still plenty to do, like changing the colour scheme, adding the banner graphic, tweaking the odd setting here and there so I have added a new thread in the 'Technical Issues, Bugs and Feature Requests' forum for you to add any issues you find, any missing settings or just anything you'd like to see added/removed from the feature set that Xenforo offers. We will get to everything over the coming weeks so please be patient, but add anything at all to the thread I mention above and we promise to get to them over the next few days/weeks/months. In the meantime, please enjoy!

Reclaimed bookcase - finished

Hand tools galore compared to my selection Andy. Is that a saw plate guide on the mitre box?
Yes, there's a pair of guide plates on a separate casting, which can be adjusted vertically and clamped where you need them. There's also an adjustment for how far apart they are, so it can adapt to suit any thickness of saw plate and always run smoothly.
Another advantage compared to some models is that there aren't lots of little bits to get lost. However, it doesn't let you set a partial depth of cut like some do, but I expect that's a feature that's not often really needed.
 
Well, the good news from down here is that despite various non-woodwork distractions, I have been able to find a few hours more. Not quite as much to show for it as last week, but I have now made up my mind about the back and how it will go. I don't seem to have taken as many photos as usual either - sorry!

I've done several more minor repairs to places where the tongue had broken off, by trimming back and gluing on a fragment cut off an offcut.

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I've sanded all 11 back pieces, on both sides, to clean them up a bit. (It's cool enough to have the vacuum on, to use with an Abranet hand pad. Nice and dust free.) I remembered that, about a decade ago when I made a batch of knotty pine boxes, I treated all the knots and resin pockets with sanding sealer, reasoning that it's basically shellac, which is what knotting is, and then a coat of water based polyurethane. I've not seen any resin problems on those boxes. As I still have enough sealer and poly, I'm doing the same on this project and have already sealed the inside of the back. I'll give everything a sanding and a first coat of both before assembly.

Having decided that the back will indeed be made of 3/8" thick matchboarding, I was able to cut the rebates where it will fit. These are 3/8" deep and 1/2" wide. Since they are on the verticals, with the upper end hidden under the top board of the bookcase and the lower end hidden on the floor, the rebates can run all the way through, with no messing about making them stopped.

Out of all the options available I took the line of least resistance and used the same onion plane as before.

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It's not really necessary but I did mark out the width and depth first. The first piece had some big wavy knots at the edge, so I took the precaution of carving away some of the hardest bits with a chisel before planing. This helped.

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Just for a change, I planed some of the depth with a more basic rebate plane. This particular one has no maker's name on it but does have a nicely fitted boxwood sole from a previous owner. It's the first wooden plane I bought.

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I think it was a bit quicker too, easier to hold straight and a close fit to the size of rebate required. It's not hard to plane down to a line.

Both planes could take quite thick shavings, which is what you want to do really, unless you have a use for fine wispy firelighters.

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Here's a really dull shot of a bit of planed rebate, showing that the surface through the knot is not as smooth as I would aim for on a table top or a picture frame, but is ok for a hidden constructional detail:

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And there was another one of these to go in the garden refuse bin:

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One thing I have been wondering about is how to fix the boards on. The old cupboard had two nails on the ends of each board every board had two splits where the nails had been. From the scars I can see that they were thickish headed nails. I trimmed the splits off when cutting the boards to length.

So, should I just use one nail per board or can I get away with two? I have plenty of thin, bendy panel pins in various lengths, which I don't think would put up much resistance to a bit of sideways pressure. And these boards are probably about a century old and might not do much seasonal movement now anyway. I don't want them dislodged if the user slams a heavy book or box into place, so two pins would be more secure.

Opinions and suggestions welcome!
 
Andy, are you only fastening the boards only at the top and bottom or are the middle shelves to be secured in place?
 
Andy, are you only fastening the boards only at the top and bottom or are the middle shelves to be secured in place?
Just top and bottom so all three shelves are adjustable, on metal library strips.
 
Got it, my suggestion might be wrong , I would drill two holes per board end larger than the nail shank so you won't cause a split when driving in nails. I like using ring nails as they grab nicely into wood. And a dab of glue in the groove of each board half way along. If there is to be movement side to side then the boards have room to move?
 
Are the boards square-edged? If so, do you have enough of them to put a rebate on each edge and have half-laps? If so, you only need one nail per board, because the leading edge of one board then traps the trailing edge of the next, and yet leaves room for expansion and contraction. Or, knowing you, you'll have a tongue and groove plane (or set thereof).....and T&G produces the same effect.
 
Are the boards square-edged? If so, do you have enough of them to put a rebate on each edge and have half-laps? If so, you only need one nail per board, because the leading edge of one board then traps the trailing edge of the next, and yet leaves room for expansion and contraction. Or, knowing you, you'll have a tongue and groove plane (or set thereof).....and T&G produces the same effect.
They are all T&G.
 
When I made a bookcase with a boarded back, I T&G them and used one small brass C/S screw per board. My thought was if any book gets pushed back too abruptly, the back won't come off !
 
I would go for one brass CSK screw in each end of the boards, mostly because I was given lots of screws.
A blunted nail will not split the board bit might work lose.

Pete
 
Thanks all for the suggestions. I'll ponder a bit and decide when I get back to the workshop.
 
They are all T&G.
So one nail adjacent to the join holds everything down, but allows movement. If you can organise to start (or finish) with a half-width board it will help because that particular board needs a nail to both edges.
 
My continuous run of days in the workshop got interrupted, but I have managed to move on with a few bits and pieces, so here's a not-quite-final update.

When I left off I was thinking about the back and decided on the reclaimed matchboarding, plus a little bit extra.

This has now all been sanded to clean it up and had a coat of sanding sealer shellac applied to the front, then a coat of water based polyurethane on both faces. That all looks like this:
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Also getting a first coat of finish are the toe board, the base and the rails to go across the top.

The new bit of matchboarding got an extra layer of shellac so it's not quite so pale as it was.

It's a big advantage, even in this hot weather, to be using finishes that dry so quickly - with that lot filling up the bench I don't want an enforced 24 hour wait. Also, they are both really easy to apply and brush out even.

To hold the shelves in place, I decided to use some reclaimed metal library strip. When I built a little ash bookcase, decades ago, I used the prettier flat sort, which needs a wide shallow groove behind it, with a deeper groove in the middle where the tabs protrude. This stuff should be easier, as it just screws on. Now that the insides of the uprights had been finished, I set to on those, using the workmate while the bench was full.

This was easy but took quite a long time. I lined the pieces up just above the base and used a couple of small combination squares to measure the same distance in from the edges. Then each hole got poked with an awl, and a little screw was put in.

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With tiny screws in softwood, the holes don't need drilling. I used this little Horace Britton tool handle, patented November 28, 1893. The metal cone screws down onto a split shaft, which holds any of a collection of little tools stored inside. Neat and effective, but I think the four-sided awl is the only one I've actually used...

Anyway, this all took a while, as there are nine holes in each strip.

There's another downside to using this sort of surface-mounted strip, that if I cut the shelves square, to fit between them, there would be gaps of about 3mm at each end. I decided I didn't like that, so spent several hours fiddling about cutting little notches on the ends of the shelves.

First, I had a dummy run on an offcut, to confirm the dimensions. I then used this offcut to line up the saw when notching the six shelf ends.

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I knifed a baseline and pared all the wood out with a chisel, as if I was doing shallow dovetails. It was a bit of a reminder that redwood isn't always easy to work with, because of the very hard layers alternating with the much softer ones.

I managed to make them all to a standard I thought was good enough for something not actually visible. Tool spotters have probably seen this perfectly commonplace half inch bevel edge chisel before, but it's the one I choose first for a job like this. It's a proper bevel edge, with very fine lands, even if the shaping around the tang and the bolster is pretty crude.

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(That rather poor mark says F. WOODCOCK SHEFFIELD, which puts it between 1922 and 1957. When the company was wound up so the directors could retire, their stock of forgings was bought at auction by Ashley Iles - which helped him get started in business. A 10-ton lorry full, for £40!)

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I found I got best results by making a sloping surface with the first cuts, so I could then pare horizontally, moving down the slope in tiny steps, from one side, then the other. The last slice reveals the shiny knife cut. I didn't photograph all of this, as I'm sure it's familiar stuff, but here's a half-way shot and a finished notch.

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With all twelve notches cut, I could test fit the shelves into place.

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They fitted ok, just resting on the metal strips while the unit is still horizontal.

There's still quite a bit of sanding and finishing to do, and the back to fix on. I need to do everything in the right order so I don't spoil the finished surfaces.
 
I've belatedly realised that I missed out a really exciting stage of this bookcase build when I posted yesterday - the glue-up!

Thinking it might be a bit awkward (what with there being less than an inch of space to spare if I stand it up etc) I had a dry run. Here it is, on a tidied up bench. There's one long steel sash cramp holding the base into the sides, with a lighter weight wooden version on the top. The dovetailed rails are just looking after themselves. Offcuts make it level with the big sash cramp. It checked out ok for squareness.

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So it was time for the real thing.

Expecting difficulties, I used my usual favourite, liquid hide glue, to get easy application, easy clean-up and longish open time.

But having had the rehearsal, it took less than fifteen minutes to get to this stage:


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Can you spot the difference?

Yes, there's a smidgen of surplus glue on the dovetails. And a smile on my face! :giggle:
 
With the glue set, it was time to fix the back. To save my back and knees I kept the bookcase face down on the bench. To protect the varnished edges, I used a picnic blanket.

I started on one side with the new piece, following with all the reclaimed strips. I drilled holes with a little cordless screwdriver to avoid splitting and used an assortment of nails, mostly small wire nails with flat heads. The first and last boards got extra nails to secure them in the rebates but the rest had just one each, relying on the T&G to hold the un-nailed edge. I snugged the boards up by holding a bit of ply alongside the tongues and tapping gently with a soft faced hammer.

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I had thought that I would need to saw the edge off the last strip but in the end it needed just a couple of passes of a blockplane to fit.

I stood it up on the bench and slid the top board into position. (I'd already trimmed it to length and applied more iron-on edging and the first coat of water-based poly by this stage.)

There was enough room for some slim clamps to hold the board in place, carefully lined up all round with combination gauges, like I did with the library strips. It doesn't matter what the exact overhang is, but it does need to be the same at each end.

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I could then temporarily insert eight screws, upwards through the holes I had already drilled and countersunk in the horizontal rails.

This was followed by some more sanding and finishing on everything. The inside and outside of the case got another coat of polyurethane. The shelves got sanded all over and a coat of shellac sealer, then a coat of poly, and a second coat on the upper surfaces.

When everything was dry, I could screw the top on, position the shelf supports and place the shelves at random. I'm pleased to say that there was just enough room to pivot the shelves into place and that the notches have the extra effect of preventing the shelves from pulling out forwards at all.

And so, here's the final photo.

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When it cools down a bit I can take the too-wide top off the bookcase, fit the body into the back of the car and deliver it, together with the top, the shelves and a set of screws. I hope it will prove useful to its new owner.

I've really enjoyed making it and sharing the build with you all, knowing that nobody else will ever think quite as closely about the options, methods and details as a bunch of friendly and supportive woodworkers.
 
Nice job. Even though it is really a tool thread. :cool: Very good wip and good to reclaim materials.

Surprised you did not rebate the library strips in. Is there any centre support for the shelves? I only ask because I haev about 2 million cookery books and a lot of them are thick and heavy and would bend stone.....
 
Nice job. Even though it is really a tool thread. :cool: Very good wip and good to reclaim materials.

Surprised you did not rebate the library strips in. Is there any centre support for the shelves? I only ask because I haev about 2 million cookery books and a lot of them are thick and heavy and would bend stone.....
This sort of strip is definitely designed for surface mounting, unlike the plain flat sort which needs grooves as shown here on the right of the photo:

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There's no central support, but that's ok in this case as the recipient doesn't have any cookery books... some of the shelves will get filled with lightweight boxes of electronic stuff, which is easier to store, even if it's hard to keep tidy.

And I admit that some of the motivation was to use my tools and some was to use up accumulated bits of useful wood!
 
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Books. It's an addiction. I'm hoping to get treatment for it. Maybe benefits as well.
 
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