Lee Valley Tools    Woodworking Newsletter
   Vol. 5, Issue 2
   November 2010
 
   Mission Style Bookcase
 

Foot detail   Bark inclusion fix
The foot detail shows hidden triangular support blocks, to provide strength, and cork discs, to protect the floor.   The author repaired a bark inclusion that left a soft spot on one board using a tenon cutter and new wood.

The sides extend down below the bottom shelf to form feet, and cork discs stuck in shallow countersinks protect the floor. The middle vertical frame member fits in 1/4" deep dados in both the top and bottom shelves. These dados are stopped so that they aren't visible from the front of the shelf. The three vertical members and the top and bottom shelves form a rigid frame, while the remaining shelves (three on each side) rest on adjustable pins. These six floating shelves were assembled separately: I glued up each surface from two pieces of walnut, with a third piece glued on the back to provide a shallow vertical backstop so books don't slide off.

Overall, the cherry used for the vertical members was clear and consistent; however, there was one area containing a bark inclusion that left a soft, inconsistent spot on one board. I oriented this so that it was low on an inside face, but knew that the soft wood wouldn't hold a shelf pin well. So, I drilled out the inclusion and replaced this spot with new wood. Since a majority of the area could be covered by a 1" diameter circle, I selected a 1" Forstner bit and drilled down until I saw mostly clear wood at the bottom of the hole. I used a 1" tenon / plug cutter to create a replacement face-grain plug out of a cutoff from the same board so that the color and the grain would match as closely as possible. I oriented the plug so the grain was facing the same direction as the surrounding wood and glued it into the hole. I trimmed it using a flush-cutting saw and smoothed it with a plane. (The matching grain directions helped a great deal with this.)
 
 
             
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