Library Bookshelf

[nelsonic]

building a custom full wall book case to store/organise our books.

Standard book sizes: https://www.printondemand-worldwide.com/resources/printondemand-worldwide-book-size-guide/

Book sizes in cm and mm

• Standard (19.7cm x 13.2cm) (197mm x 132mm) – Our standard book size.
• Novel (20.3cm x 12.7cm) (203mm x 127mm) – A popular size for trade paperbacks in the UK.
• A5 (21cm x 14.8cm) (210mm x 148mm) – This size is usually used for novels, notebooks, and pocket books.
• Demy (21.6cm x 13.8cm) (216mm x 138mm) – The type of fiction you would see in a UK airport tends to be Demy – because it is slightly larger than UK trade books and attracts more attention.
• US Royal (22.9cm x 15.2cm) (229mm x 152mm) – American trade books come in this bigger size.
• Royal (23.4cm x 15.6cm) (234mm x 156mm) – Slightly larger than the US trade size and will also suit hardcover books.
• A4 (29.7cm x 21cm) (297mm x 210mm) – A4 is the standard size used for many magazines and catalogues.
• Square (21cm) (210mm) – We like this size for full-bleed images when using landscape or portrait formatting.

The full height (floor to ceiling) is 2770 mm. We need 10cm ground clearance underneath the bottom shelf so the Roomba #122 can clean under it so that it doesn't become a dust magnet.

The baseboard is 70mm so we need 30mm of material to prop up the bottom shelf if it rests on the baseboard.

2770 - 100 - 335 - 630 = 1705 1705 / 275 = 6.2 -> 6 shelves.

Going to make:

• 3 shelves 30cm tall for larger books, folders, etc.
• 2 shelves 22cm tall for Non-fiction and the occasional intellectually stimulating novel.
• 6 shelves 226cm tall for all the remaining books (of which 98% of our computer programming books will fit)

Going to draw this out on Ply board so I can get it cut today after work.

[nelsonic]

2835 LED Strip lights are the most modern type: https://hitlights.com/blogs/premium-led-strip-lighting/numbers-and-leds-what-does-2835-3528-and-5050-mean

[nelsonic]

Placed an order for these LEDs: https://www.lightinthebox.com/en/p/zdm-3m-light-sets-180-leds-2835-smd-1set-mounting-bracket-1-x-12v-2a-adapter-1-x-pir-sensor-warm-white-cold-white-waterproof-new-design-self-adhesive_p6902528.html

But not expecting the LEDs to arrive for another couple of weeks ... ⏳

Luckily, the design for the shelves does not require the LEDs to be here before assembling and mounting the shelves. I will mount the light strips retrospectively. A bit more work but not the end of the world. 🙄

Going to visit Leroy Merlin tomorrow (Sunday) afternoon and get the 5 sheets of Plywood cut. There are 33 pieces to be cut, loaded into the car and brought back home. Then there are another 44 smaller cuts to be made in our workshop. This is easily the biggest item of furniture I've built so far in the house. I estimate that it will take me the whole week (of evenings) to get it all done. 4 x 4h ... ⏳ 👷 Verrrrry keen to get this done as it will make a huge difference to our entrance... 🤞

[nelsonic]

Went to get the Plywood cut at Leroy Merlin yesterday:

I explained to the chap doing the cutting that the cutting lists https://github.com/dwyl/home/tree/master/library carefully maximised each board to minimise waste:

But sadly he did not follow my precise instructions ... So there are quite a few pieces that are wrong. 🤦

This photo shows the cut pieces loaded in to @carolrmc's car: (thanks again for lending it to me!)

That extra large piece on top is just one of the mistakes. It's not in my cutting list/diagrams ...

Suuuuuuper annoying. Gives me quite a lot more work (a) figuring out what pieces are missing and (b) cutting them myself from full Plywood boards or having to go back to the store to get new boards and cuts ... ⏳

[nelsonic]

Also, fun fact: The wall where I will be installing the shelves isn't flat/square. 📐 This is the gap in the between the shelf and the wall at the middle of the shelf:

This is going to make life interesting ... 🙄

[carolrmc]

What a palava! Just to add to your headache 🤕

On Mon, 26 Jul 2021 at 13:40, Nelson @.***> wrote:

Also, fun fact: The wall where I will be installing the shelves isn't flat/square. 📐 This is the gap in the between the shelf and the wall at the middle of the shelf: [image: wall-gap] https://user-images.githubusercontent.com/194400/126989924-8804a74e-accf-4af8-8f4a-836cdb55736d.png

This is going to make life interesting ... 🙄

[image: mind-the-gap] https://user-images.githubusercontent.com/194400/126990247-71b10439-505f-43d2-bbbc-c122653fda82.png

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[nelsonic]

Yeah, you wouldn't want life to be easy ... 😜

[carolrmc]

🤨

On Mon, 26 Jul 2021 at 13:54, Nelson @.***> wrote:

Yeah, you wouldn't want life to be easy ... 😜

[image: image] https://user-images.githubusercontent.com/194400/126991864-195b404d-7947-438b-9571-5a44f5d2c6e5.png

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[nelsonic]

I side-tracked to build the entrance shoe rack: https://github.com/dwyl/home/issues/181 👞 👟 🥿 And a bunch of other work-related tasks ... ⏳

Going to resume the library shelving ASAP as my next highest priority DIY/Furniture task.

Currently waiting for delivery of a 15mm Groove Cutting Router Bit: https://www.amazon.co.uk/gp/product/B000XJ0CR4/?th=1

I'm going to have to cut 40+ groves and I only have a 12mm bit ... It's fine to do 2 passes for the other small items of furniture I've built. But having to do setup for 80+ cuts (two passes for each groove) is mega tedious.

So patiently waiting for delivery from the ES AMZN which was cheaper than UK:

[carolrmc]

Patience is a virtue … On Thu, 6 Jan 2022 at 11:55, Nelson @.***> wrote:

I side-tracked to build the entrance shoe rack: #181 https://github.com/dwyl/home/issues/181 👞 👟 🥿 And a bunch of other work-related tasks ... ⏳

Going to resume the library shelving ASAP as my next highest priority DIY/Furniture task.

Currently waiting for delivery of a 15mm Groove Cutting Router Bit: https://www.amazon.co.uk/gp/product/B000XJ0CR4/?th=1 [image: image] https://user-images.githubusercontent.com/194400/148378877-595ff21c-f420-4faa-a3c3-87f78028d223.png

I'm going to have to cut 40+ groves and I only have a 12mm bit ... It's fine to do 2 passes for the other small items of furniture I've built. But having to do setup for 80+ cuts (two passes for each groove) is mega tedious.

So patiently waiting for delivery from the ES AMZN which was cheaper than UK: [image: amazon-spain-router-bit-purchased] https://user-images.githubusercontent.com/194400/148379287-99a594fa-b2cc-4b11-816d-89fd1677fdc8.png

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[iteles]

Can't wait for this, it'll make such a difference ❤️

[nelsonic]

Going to focus on this on Saturday. 🤞

[iteles]

Could not be more excited. Totally making time to sit with you and do some of this.

[nelsonic]

Yesterday (Saturday) I got off to a slow start because I didn't have everything ready... ⏳

I had to make two jigs for routing (cutting) the grooves into the shelves; this is the jig that turns my Makita RT0700C hand router into groove cutter:

I have a Bosch plunge router (that I've owned for 10+ years) but the collet is 6mm (the part that grips the router bit) so it does not fit the new bit I bought for this project ... see above: https://github.com/dwyl/home/issues/179#issuecomment-1006520879 ⬆️ hence having to adapt the Makita (which has an 8mm collet) from a palm (detail) router which has a circular base that makes it tricky to cut straight lines ... to now have a flat edge that can track my straight line jig.

Speaking of straight line jigs, this is the one I made for reliably routing the groves in the shelves:

It doesn't look like much, but it dramatically simplifies the groove routing process so I can route each groove in about a minute including measuring, setup and cutting. So I could have all the groves for the shelves done in about 30 mins!

If you're new to routing in the context of woodworking, see: https://en.wikipedia.org/wiki/Router_(woodworking) And watch a few YouTube videos to get an even better idea, e.g: https://github.com/dwyl/learn-cad-cam-cnc/issues/42

This is my outdoor work area: (I work outside because I don't yet have a dust collection system in the workshop ...)

In this picture you can see my mitre saw, table (job site) saw, router table and makeshift workbench.

I managed to fully assemble one shelf yesterday:

This is what the front of a shelf looks like with the vertical support slotted into the groove:

And here is a side-view of the end of the shelf showing the concealed French cleat attached to the shelf:

Here's a shot of one of the supports from under the shelf:

Note: this is not "finished" yet; it still needs to be hand-sanded with 200 grit sandpaper and tidied before the clear-coat varnish is applied ... but you get the idea of the joinery.

Production Plan

Now that I've successfully built the prototype shelf, my next step is to "productionize" the process.

For the cutting & joining of the 9 remaining shelves, I need to:

• [x] Route (cut) the 4 groves into each shelf using the hand router + Jigs: 4 x 9 = 36 (30 mins)
• [x] Route the back underside of each shelf on the router table: x 9 (10 mins)
• [x] Assemble/glue the French cleat for each shelf and allow 2h to cure x 9 shelves (60 mins)
• [x] Rip 7 x 150mm pieces from the 15mm ply boards for the vertical supports (10 mins)
• [x] Measure & chop the 4 vertical supports for each shelf 4 x 9 = 36 (60 mins)
• [x] Lightly sand each vertical support to deburr (avoid splinters during assembly) > (30 mins)
• [ ] Glue each vertical support in the slot 4 x 9 = 36 (60 mins)

Once the 10 shelves are assembled, mounting them to the wall should be relatively easy because of the (locking) French cleat system. The steps are:

• [ ] Measure and mark the holes for each French cleat (bottom) 4 x 9 = 36 (10 mins)
• [ ] Drill the 4 holes & counter-sink each hole 4 x 9 = 36 (30 mins)
• [ ] Measure the height we want the top of each shelf to be at. (20 mins)
• [ ] Use the Stanley laser level to draw the perfectly level line on the wall for each shelf (10 mins)
• [ ] Mark the holes for mounting the French cleat to the wall. (10 mins)
• [ ] Drill the holes 4 x 9 = 36 (30 mins)
• [ ] Insert Rawlplugs into each hole 4 x 9 = 36 (10 mins)
• [ ] Screw the screws into each French cleat strip (10 mins)
• [ ] Soft-mount each shelf in place (20 mins)

Once we have soft-mounted each shelf we can bring them back down to the workshop and make any adjustments before finishing (hand-sanding and varnishing) each shelf prior to final mounting with locks.

[nelsonic]

Yesterday I measured and routed all the groves for the shelves:

Sadly, I was distracted and made a mistake with one of the shelves. (The one on the right in this picture) but it’s ok, I think I might be able to use it for something improvised. 💭

Here’s a bit more context for how the jigs work:

By the end of the day I had mounted all the French clear strips to the shelves:

[nelsonic]

Next in the production plan:

Rip the support pieces on the table saw (150mm) and then chop them down to size on the mitre saw. 🪚

Going to try and get this done this evening. 🤞

[nelsonic]

Got a warning saying there was a critical security update for MacOS: 🐛 https://www.kaspersky.com/blog/webkit-vulnerability-cve-2022-22620/43650/

so I set my Mac updating at lunch time ... ⏳

Used the fact that I couldn't do work-work to spend a few mins (of my lunch break) cutting the 150mm strips:

Only did 6 because I think it might be enough ... 🤞 (still have the table saw setup so can easily cut more if needed) Took me less than 5 mins because the saw fence was already setup so I just had to run the board through the saw.

So the next step tonight will be to cut the vertical supports on the mitre/chop saw. 🪚 Looking forward to getting it done ... But need to focus on my work-work now. 🧑‍💻

[nelsonic]

Made decent progress this evening. Cut and Prepared the vertical supports for the 8 shelves:

glued the supports for 4 of the shelves. Will do the rest tomorrow.

had a visit from the supervisor while gluing-up the supports for a shelf.

[nelsonic]

Super not to scale, but this is the positioning for the 9 shelves we have:

going to do the laser measuring tomorrow evening, then drill on Thursday and mount on Friday. 🤞

[nelsonic]

Transferred the levels/measurements to the wall using the laser level:

All the French Cleats strips are ready to go on the wall tomorrow:

And the bottom shelf is gluing:

[nelsonic]

I need to buy more clamps …

[nelsonic]

Finished installing the shelves on the wall:

In the middle the shelves are level:

But on the ends some of them are not. It's mega frustrating. But I've learned several valuable lessons in the process and already know exactly how I would build them differently "next time" ... To counteract the non-flat wall by using 3 vertical strips of wood fixed to the wall at various points. Then fix the shelves to the vertical support. The end result would be far more consistent.

Anyway, not going to re-do it now as it would be a huge waste of materials and time. Just going to get on with using it for books and will do it much better next time.

[carolrmc]

Already looking quite busy❗️👏🏻

On Sun, 20 Feb 2022 at 21:39, Nelson @.***> wrote:

Finished installing the shelves on the wall:

[image: image] https://user-images.githubusercontent.com/194400/154865126-786bbc52-362f-4558-b8ad-49e17f642471.png

In the middle the shelves are level:

[image: image] https://user-images.githubusercontent.com/194400/154865144-f3392a0a-ffc3-45e7-b7e1-0d714816b23a.png

[image: image] https://user-images.githubusercontent.com/194400/154865154-802d05fb-509b-4971-89d7-4598c108d6ab.png

But on the ends some of them are not. It's mega frustrating. But I've learned several valuable lessons in the process and already know exactly how I would build them differently "next time" ... To counteract the non-flat wall by using 3 vertical strips of wood fixed to the wall at various points. Then fix the shelves to the vertical support. The end result would be far more consistent.

Anyway, not going to re-do it now as it would be a huge waste of materials and time. Just going to get on with using it for books and will do it much better next time.

[image: image] https://user-images.githubusercontent.com/194400/154865308-d07364e0-5283-455a-851e-fce0240a6f93.png

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[nelsonic]

@carolrmc indeed. I've unpacked quite a few boxes already. Took this photo Saturday night. It already looks quite different. Will update once all the books are unpacked. Might need more shelf space ... 🙄

[carolrmc]

Die Appel val nie ver van die boom nie🥰

On Sun, 20 Feb 2022 at 21:58, Nelson @.***> wrote:

@carolrmc https://github.com/carolrmc indeed. I've unpacked quite a few boxes already. Took this photo Saturday night. It already looks quite different. Will update once all the books are unpacked. Might need more shelf space ... 🙄

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[nelsonic]

@carolrmc indeed. 🍎 🌳 📚 ... But when we build our next house in a forrest it will have an expandable/extendable library so we never run out of space for books. If we read too much, and need more space, we'll just add it. 👍

e.g: https://youtu.be/E8Bq4DbMaRU?t=470

[nelsonic]

Stoked that we built the extra shelves: https://github.com/dwyl/home/issues/190#issuecomment-1052675411 ✅ We almost have enough space for our books now ... 📚

[nelsonic]

https://www.goodreads.com/quotes/82833-rich-people-have-small-tvs-and-big-libraries-and-poor

[nelsonic]

This is what the library Shelves look like today: (thanks to @Stephanymtr in #216) 🎉

Still want to make more shelves #215 to avoid having books horizontal ... 😕 But thinking of something even more ambitious for that! 😜