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WAVE SHELF
Gather your supplies
ITEM PART SIZE MATERIAL
A1,A2
Side (makes 2) 1800 x 610 x 17mm Plywood
B1-B6
Shelves (3 make 6) 795 x 510 x 17mm Plywood
C1-C6
Backs (6) various 597 x 17mm Plywood
All components are cut from one sheet of 2400 x 1200 x 17mm hoop
pine plywood.
line down the centre
of sides (A). Measuring
from the bottom, mark
in intervals of 595mm
along the line. Also,
draw set-out lines
down the centre of
the shelves (B).
Step 3
The set-out lines
on the backs (C) are off-
centre. Referring to the
diagram, on C1,C2, the
set-out line is 155mm
from the C1 side, on
C3,C4, it is 115mm from
the C3 side and on
C5,C6, the line is 55mm
from the C5 side.
Step 4
On a strip of
cardboard or thin piece
of plywood, make up
templates for the curves.
Either use the templates
here or draw your own
arcs with a radius of
455mm for the sides
and shelf backs, and
800mm for the shelves.
The segment height
used for the waves is
only 25mm deep. Cut
out the templates.
to each 595mm mark to
get the repeated pattern
of successive waves.
The templates are used
full length to mark in
curves on the backs
and shelves. Mark
each of the shelves
and the backs to
keep them in their
correct positions.
Step 6
Along the
straight back of the sides
and the curved front of
the shelves, mark in slots
for the cross-halved joints
as shown in the diagram.
These slots enable
the assembly of the
interlocking components.
each corner, working
on the waste side of
the set-out line, then
across to the opposite
corner to leave a little
triangle at the slot end.
Use a chisel to clean
out the remainder.
Check the fit of an offcut
of the plywood – it
should be a snug fit.
If necessary, sand the
inside surfaces of the
slot to ease slightly.
Step 10
After preparing
the 2 sides, 6 shelves
and 6 backs, give a final
sand, then apply 3 coats
of polyurethane, sanding
lightly with 320-grit
paper between coats.
You’ll also need
800 x 100mm cardboard or thin plywood strips; 22mm hoop pine edge
veneer; PVA adhesive; 40mm wood screws; colour-matched plastic screw
caps; wipe-on polyurethane
Here’s how
Step 1
Before setting
out the sheet, give it
a sand all over. Using a
soft pencil, set out the
sheet into rectangles as
shown in the diagram,
leaving room between
pieces to allow for the
width of the saw cut
(about 3mm). Cut out
the rectangular pieces,
which are shelf pairs,
before marking in and
cutting the curves. A
power saw with a sharp,
fine-tooth blade will give
good results. Cut along
a straight edge, set to
allow for the distance
between the blade and
the edge of the saw
base plate. If you can’t
cut them yourself, a
timber yard can cut
them into pieces for
you for a modest fee.
Step 2
Referring to the
diagram, draw a set-out
Step 11
Slot in the top
and bottom shelves,
tapping in with a rubber
mallet. Install the other
shelves, alternating the
waves with each shelf.
Step 9
Veneer the
side edges, then the
wavy front. Place
the veneer glue side
down on the edge, then
set a household iron to
hot and run it over the
veneer, to melt the glue.
The glue should be
melted in 10 seconds
and will stick as soon
as it cools. Follow this
immediately with a
soft wooden block to
ensure the veneer is
well glued. Cut out the
slots on curved edges
of shelves after the
veneer has been glued
in place. As you iron
each piece, trim around
the edges with a utility
knife, then lightly sand
to clean up the edges.
Shopping:
Wave shelf
developed and built
by
Neil Wing, 0417
977 341
. Hoop pine
plywood and edging,
Pearson Plywood &
Panel Products, (02)
9743 0999
. Wipe-on
polyurethane,
Globak
Paints & Chemicals,
(03) 9533 1913
.
Sundries,
Mitre 10,
13 63 10
. Skynar floor
lamp $69; Branas
baskets $15 each;
Respekt, Stilleben
vases from $6 each;
Raket photo frames
$3.95 per packet,
IKEA
nationally.
Step 7
Before cutting
out, fit a splinter guard
(which may be an
optional accessory) to
your jigsaw, to lessen
the chance of wood
breaking out at the top
surface as the jigsaw
cuts upwards. Cut along
the curved lines.
Step 12
Predrill screw
holes to take countersunk
screws, then screw on
backs with 3 screws
from underside of each
shelf and 1 from each
side. The crest of a back
wave should correspond
with the trough of its shelf
wave. The largest back
goes at the base, with
each one above being
the next size down.
Step 5
Align the
templates with the set-
out lines on the shelf and
back components, and in
the case of the sides,
slide the template along
All measurements in mm
Step 8
When cutting
out the slots, cut into
Use a splinter guard on your jigsaw to surf the waves without wipe-outs
JUNE 2002
This shelf can be made from a single sheet of
furniture-grade plywood, which costs less than $100.
Building it is a breeze – all you need is a jigsaw, a
power saw, if making the large, straight cuts yourself,
a household iron and standard woodworking tools.
This unique
bookcase is
wonderfully
arty – it breaks
away from the
boxiness of
standard units
Side template
Shelf template
square = 25mm grid
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