Instructions:
Cut the 5x5' sheet using the circular saw, and the guide.
I opted for 29 7/8"x 19 7/8" shelves. one, I wanted something roomy, and secondly, I didn't want to waste a square inch of that 40$ sheet of plywood.
so I measured it up, marked my cuts, and clamped my cutting guide down 4" behind my cut line for the circular saw base.
in this manner I cut 6 equally sized pieces.
I cut one piece of MDF exactly 1.5x1.5" smaller than the ply.
this I measured, found the center, and marked that.
marking 2" all around the edge, and marking the center line 2" wide.
I used the drill with the 1/2" bit on all 8 corners of the 2 marked rectangles on the MDF. this makes for good spots for the jig saw blade to move around. using that, I cut out the rectangles, followed with 3/4" slots for the sand to enter in.
then I cut 3/4" strips out of the maple board with the table saw.
once all the pieces were cut, it was time to assemble my top shelf using glue, and lots of clamps.
this was done in steps. first I glued the MDF centered on one of my ply pieces. then glued the maple strips on the front, and sides, leaving the rear with the 2 entry points for the sand still exposed.
then I glued on the second sheet of ply.
once this was set, I marked where the threaded rods would go, 2" from the edge, one in the center back, and 2 in the front.
Using the drill press and the 5/8" spade bit, I drilled the holes on all shelves.
a good sharp spade bit will always make for a much cleaner hole. no chipping around the edged of the hole. i bored until about 3/4 of the way through, and flipped it over to finish on the other side. this ensures clean edged on both sides.
on to the sanding
I bolted all the shelves together using the 3 holes I drilled.
Using the belt sander, with first the rougher grit belt, and followed by the finer one, I sanded the edges of the shelves. this made for a nice uniform finish, and dimensions.
then with the orbital, did the finishing with the 2 grades, rough then fine.
taking the bolts out, I sanded all the surfaces until it was nice and smooth.
Filling with sand.
quite easy, acquire dry sand, and use a funnel to slowly fill the two chambers, thumping it down on a rolled up old towel on the ground to settle it in nice and tight.
once filled, I took the 4th strip of maple, slathered 3 sides in glue, and gently tapped it into the slot on the back of the shelf using a hammer, sealing the sand in.
this was followed with a very quick sanding to finish off that end.
Varnish.
I applied one coat to each surface, and allowed it to dry for 6 hours.
then I sanded all the pieces again with the 320 grit paper to ensure smoothness
I then applied 2 more coats of the varnish.
All that remains is assembly, and this I will get to tomorrow.
Pics to come of the finished product.
