Support Brackets for Library Bookshelves

[nelsonic]

Sadly, the Construction Grade Plywood I used to make the South Wall Library Bookshelves https://github.com/dwyl/home/issues/190 was not very strong ... 😢

Long story short, I need to make 4 trusses for the shelves that have most weight on them. I will make them out of "found" materials in the workshop and I expect it to take me around T2h.

Todo

• [x] Measure the space.
• [x] Measure the available "found" materials (off cuts from previous projects)
• [x] Confirm we have enough material for at least 4 trusses
• [x] Cut and construct the first truss as a trial
• [x] Test mount it!
• [x] Make 3 more trusses and mount them.

[nelsonic]

This is the laser portion of this mini project:

[nelsonic]

Just going to run this quick experiment to see how fast/intense I need to etch a groove instead of routing it...

[nelsonic]

Turns out that doing a "fill" 20 mm @ 80% power is basically nuking the 15mm plywood. So I decreased the two test fills to 100mm @ 80% and 150mm @ 80% which were both good. The 100mm @ 80% is best as a viable alternative to using the router table to cut grooves. But I think I will just setup the router table now and do the routing tomorrow instead of burning them. I was just trying to do it on the Laser to avoid making noise but it's not a good replacement. (illustrative photos of test to follow ...)

[nelsonic]

First one:

All 6 ready to be mounted:

will resume this when we get home tomorrow. ⏳

[nelsonic]

I’ve done the prep work to tidy up the 3 shelves that suffered from material weakness:

and calibrated and setup the two machines I need to use tomorrow evening (or whenever I have 5 mins of time to make noise):

I need to:

1. rip a plywood board into two 55mm strips.
2. Route the 15mm @ 5mm dept groove into both strips.
3. Cut to size.
4. Precisely drill mounting holes.
5. Mount the 3 shelves using glue & screws
6. Fix to wall
7. Measure the bracket holes
8. Drill the mounting holes for the brackets (6 x 4=24)
9. Mount the brackets
10. Test!!

[nelsonic]

Drilled the 24 holes and mounted the remaining 5 brackets:

confident that these will now hold 200kg+:

Tonight after munchkin is asleep I will repopulate the shelves with the books as per the photos: https://github.com/dwyl/home/issues/190#issuecomment-1069258552

Already placed the top shelf books:

just so we can hide the stepladder 🪜 and they are out of the way.

Note: in the end I made and installed 6 shelf supports. They span shelves 2 -7. But I also reinforced all the shelves with screws from behind so they are much stronger than just glue + tack nails. I figured that the top shelf was already pretty strong and has the least weight on it; no plant, slightly reduced width and hard back books which are, counterintuitively, lighter than the cookbooks which have glossy higher density paper…

the bottom shelf doesn’t have a support bracket because if it for any reason it were to fail, the “fall” is only 10cm. But I’m happy to create a bracket if you think it makes sense. We have the materials and it would be a 30min job including installation. 💭

@iteles please share your feedback when you can. Thanks! 🙏

[nelsonic]

Pressed the wrong button. 🤦‍♂️ reopening.

[iteles]

They look really good and there's no way it'll buckle under the heavy weight of all our recipe books 😉

I have nothing constructive to share as it looks great and I agree with you on the bottom shelf. Happy to help repopulate :+1: 🚀

[nelsonic]

@iteles cool. Thanks for the feedback. Closing this issue in favour of #190 assigned to you for stacking. 📚 🤞