WOODWORKS: INTERMEDIATE PROJECT

LEANING TOWER OF SHELVES

This stylish but sturdy shelf unit will neatly hold your personal things—and you can build it in a day!

It may look lightweight and easy to topple, but don’t be fooled. This shelf tower is a real workhorse. Whether you make it for holding your books
or for showcasing family treasures, the basic construction is the same, and its open design won’t overpower any room. All the materials can be
purchased in home centers or lumberyards. The only special tools you’ll need are a power miter box for crisp angle cuts and an air-powered brad
nailer (or a hammer and finish nails could substitute) for quick assembly and almost invisible joints. And you’ll have to rustle up an old clothes iron
for applying oak edge-banding material. Once you’ve gathered the materials, you can build the shelf unit in an afternoon.

In this intermediate-level project, you’ll gain experience in laying out and making angle cuts, fastening and finishing edge veneer, assembling a
piece with several clamps, and working with an air nailer. And after you build it, you’ll learn more about applying stains and finishes to enhance the
wood’s natural beauty and ensure that it’s well protected.

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TOOLS REQUIRED
Hand Tools Power Tools Miscellaneous
– Veneer edge trimmer – Table saw – Safety glasses – Minwax® Wood Finish™ Stain
– Sanding block – Jigsaw – Framing square Brush or other good quality,
– Clamps – Miter saw – 120-, 150- and 220-grit natural bristle brush (for oil-
– Orbital sander sandpaper based stains and finishes)
– Air-powered brad nailer – Clean, lint-free cloths – Minwax® Polycrylic® Brush
(or hammer and nails) – Respirator or other good quality, syn-
– Clothes iron – Gloves for finishing thetic bristle brush (for water-
– Mineral spirits (for oil- based stains and finishes)
based finishes) – Minwax® Stainable
– Water-filled metal container Wood Filler
with tight-fitting lid – Carpenter’s glue

SHOPPING LIST CUTTING LIST

Item Quantity Key Pcs. Size & Description
3/4" oak plywood 1/2 sheet (4' x 4') A 1 3/4" x 3-3/8" x 30-1/2"
1" x 3" x 8' oak boards 3 oak plywood (shelf base)
1" x 4" x 8' oak boards 4 B 1 3/4" x 5-3/4" x 30-1/2"
7/8" oak iron-on veneer 1 package (25') oak plywood (shelf base)
1-1/4" finish brads 1 small box C 1 3/4" x 8-3/16" x 30-1/2"
Foot pads (3/4" round, self-adhesive, 1 package oak plywood (shelf base)
non-skid pads) D 1 3/4" x 10-5/8" x 30-1/2"
Recommended Wood – Oak oak plywood (shelf base)
Alternate Wood – Cherry or maple E 1 3/4" x 13" x 30-1/2"
oak plywood (shelf base)
We built our unit with red oak and oak veneer plywood, but the F 2 3/4" x 2-1/2" x 4-3/8" oak (shelf A sides;
beauty of this project is that any wood species will work. One note front end only cut at 10 degrees)
when buying boards: Use a tape measure to check the “standard” G 2 3/4" x 2-1/2" x 6-3/4" oak (shelf B sides;
dimensions of 1" x 3" and 1" x 4" boards. With hardwoods, they front end only cut at 10 degrees)
sometimes vary in width and thickness. Also check the two H 2 3/4" x 2-1/2" x 9-3/16" oak (shelf C
full-length 1" x 4" boards you plan to use as the uprights to be sides; front end only cut at 10 degrees)
sure they’re straight, with no warps or twists. And always examine I 2 3/4" x 2-1/2" x 11-5/8" oak (shelf D
the ends, edges and surfaces for blemishes or rough areas that sides; front end only cut at 10 degrees)
won’t easily sand out. J 2 3/4" x 2-1/2" x 14" oak (shelf E sides;
front end only cut at 10 degrees)
WOOD FINISHING PRODUCTS K 5 3/4" x 2-1/2" x 30-1/2" oak
Recommended Finish (shelf backs for A – E)
Prep: Minwax® Pre-Stain Wood Conditioner (if using soft L 2 3/4" x 3-1/2" x 14-1/2" oak shelf cleats
or porous wood) (cut both ends with 10-degree angles)
Stain: Minwax® Wood Finish™; for a unique, rich color, M 8 3/4" x 3-1/2" x 11-3/4" oak shelf cleats
make a 50/50 mix of Wood Finish™ English Chestnut (cut both ends with 10-degree angles)
and Wood Finish™ Sedona Red (or choose from N 2 3/4" x 3-1/2" x 10" oak shelf cleats
24 Minwax® Wood Finish™ colors) (cut both ends with 10-degree angles)
O 2 3/4" x 3-1/2" x 84" oak uprights
Finish: Minwax® Wipe-On Poly Satin (cut both ends with 10-degree angles)
Alternate Finish
Prep: Minwax® Water Based Pre-Stain Wood Conditioner
Stain: Minwax® Water Based Wood Stain Island Water (or a
Minwax® Water Based Wood Stain of your choice,
available in 50 custom-mixed colors and a White Wash
Pickling Stain.)
Finish: Minwax® Polycrylic® Protective Finish Satin

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BEFORE YOU BEGIN the glue doesn’t set. Lift the ladder shelf and place it upright against a
Good craftsmanship begins and ends with good work habits, so make wall. Check it with a framing square and flex it if necessary to square
the following steps part of your routine workshop practice. If you have it up and to make sure that the uprights rest flat against the floor and
any doubts or questions about how to proceed with a project, always wall (assuming your floor is level). Attach and tighten three bar clamps
discuss them with your shop instructor. across the unit, aligned with the top, middle and bottom shelves, until
• Carefully and fully review plans and instructions before putting a the glue dries.
tool to the project lumber.
• Work sensibly and safely. Wear safety goggles when doing work that 9. The shelf is highly stable as designed, but once you’ve stained and
creates flying chips and sawdust; wear the appropriate respirator finished it, you can add self-adhesive foam gripping pads to the bottom
whenever making sawdust or working with thinners or other solvents. of the uprights. You can also fasten the top of the uprights to the wall
• At the end of every work session, clean up your shop area and put using small angle brackets and plastic screw anchors.
away all portable tools.
STAINING AND FINISHING
CUTTING AND ASSEMBLY Woodworker’s Tip: Though you may be tempted to cut short
PROCEDURE your sanding, preparation and application time, don’t do it. These
1. Use a table saw to cut the plywood shelves (A, B, C, D, E) from the tasks are very important steps in obtaining a high-quality finish.
3/4" plywood. Note that there are five different shelf depths. Remember, it is the finish, just as much as the fit and smoothness
of the parts that will have great bearing on how people judge your
2. Clamp each shelf with the best edge facing up. Sand it lightly with craftsmanship. To ensure an excellent result, follow the steps
150-grit paper wrapped around a sanding block. Preheat a clothes iron listed in this section and also the instructions the finish manu-
to the “cotton” setting and run it over the top of the edge-banding facturer puts on its products.
veneer, positioning the veneer so it extends beyond all the plywood
edges (Fig. 2). Immediately after adhering it to the plywood, run a FINISHING TIPS
smooth object, such as a chisel handle, over the tape. Let each shelf • Test the stains and finishes you are planning to use on scraps of
edge cool for a minute before trimming and sanding the edges. wood. On the back of the scrap, mark the stain/finish combination
and the type of wood. Allow all samples to dry thoroughly before
3. Cut the 1x4 uprights (O) to the length shown in the CUTTING LIST, making your final finish selection. Save your samples for quick
using a power miter saw to make the angled cuts on the ends. Use a reference on future projects.
jigsaw to taper the tops of the uprights according to the dimensions • All stains and finishes must be allowed to dry thoroughly between
shown in Fig. 1. coats. Remember that drying times can vary due to humidity and
other climatic conditions.
4. Use the miter saw to cut the shelf sides (F, G, H, I, J) to length. Leave • If you have some leftover stain or finish, wipe the can rim so that
the saw at the 10-degree setting in order to cut the angled front ends. stain or finish in the rim won’t dry out and prevent the lid from
Then return the saw to the right-angle setting and cut the sides to forming a tight seal.
length. Next, cut the shelf backs (K) to length. • Brushes used for oil-based finishes must be cleaned with mineral
spirits; for water-based products, such as Minwax® Water-Based
5. Set the saw back to the 10-degree setting and cut the cleats (L, M, N) Wood Stains or Minwax® Polycrylic® Protective Finish, clean
to length. Note: Leave the top cleats long and cut them to exact fit brushes with warm water and soap.
during assembly. To speed finishing, use an orbital sander with 120-
and 150-grit sandpaper to sand all the pieces before assembly. 10. Sand the shelf units with 150-grit paper, then move up to 220-grit
to complete the pre-finish smoothing. Use an orbital sander to remove
6. To begin assembly, lay out both uprights and all cleats to ensure that any marks or scratches, then lightly sand with-the-grain strokes by
the angles are correct so the shelves will be level when the unit leans hand. Dust off the piece and wipe it carefully with a clean, lint-free
against a wall. Then glue and nail the first cleat flush with the base of cloth lightly dampened with mineral spirits.
each upright, using five or six 1-1/4" brads on each cleat. Work your way
up using spacers made from a 1x3 (Fig. 3). Make sure the spacer is the 11. Do the staining in two steps, starting on the interior surfaces and
exact width as the shelf sides. Set the assembled uprights aside to dry. then moving to the exterior surfaces.

7. For shelf assembly, first glue and nail on the shelf backs. Next, apply NOTE: If you choose a softwood, such as pine, or a porous hardwood,
the sides with glue and nails. like maple, you’ll need to prepare it for staining with a coat of
Minwax® Pre-Stain Wood Conditioner. Applying the conditioner will
FINAL ASSEMBLY help to ensure even absorption of stain and prevent blotchiness that can
8. For final assembly, clamp the shelves to one upright as shown in occur with some soft or porous woods. Following the directions on the
Fig. 4. Apply glue to the ends of the shelves, position the second upright can, simply brush the conditioner over all thewood and allow it to
on top flush with the front edges of the shelves, then sink four 1-1/4" penetrate for 5 to 15 minutes. Then removeexcess conditioner
brads into each shelf from the upright side. Carefully turn the unit over with a clean, dry cloth.
and repeat the process to attach the second upright. Work quickly so

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Recommended Finish For this reason, make sure you look over all of the Minwax®
For this project, we’ve chosen a 50/50 mix of Wood Finish™ English color charts before making your final selection.
Chestnut and Wood Finish™ Sedona Red for a unique, rich color.
Mixing is a fun way to experiment with tones and colors. It allows you 18. After allowing the piece to dry overnight, apply Minwax®
to creatively express your own personal taste and style, and is often a Polycrylic® Protective Finish following the directions on the can.
technique that decorators and professional contractors use. Stir the can contents thoroughly before starting and periodically
repeat the stirring during your work session.
12. Apply the Minwax® Wood Finish™ you’ve chosen to the interior
surfaces using a good quality, natural bristle brush or a clean, lint-free 19. Working a small area at a time to maintain a wet edge, apply the
cloth. The brush will help you get the stain into the many inside corners first coat. Work quickly and make the final strokes in each newly
and other tight spots. Allow the Wood Finish™ to set for about 5 to 15 finished section using with-the-grain brushstrokes.
minutes, then wipe off any excess. Repeat for the exterior surfaces. To
achieve a deeper color, you may apply a second coat after 4 to 6 hours, 20. Allow the finish to dry a minimum of 2 hours. Then sand lightly
repeating the application directions for the first coat. Allow the stain to with 220-grit or finer sandpaper wrapped around a soft backup block.
dry for 24 hours before applying the protective clear finish. Thoroughly dust off and wipe all surfaces with a cloth lightly dampened
with water.
13. Apply Minwax® Wipe-On Poly following the directions on the can.
Shake the can thoroughly. Apply a liberal amount of Wipe-On Poly to 21. Repeat steps 17 and 18 to apply the second and final coat.
a clean, soft, lint-free cloth, and rub into the wood. Allow the first coat
to dry overnight. PRODUCT SAFETY
For your safety and the safety of those you work with, always read the
14. The following day, sand all surfaces very lightly with 220-grit or safety warnings, which manufacturers print on their labels, and follow
finer sandpaper or very fine (000) steel wool using with-the-grain them to the letter. Typical safety advice and instructions will contain
strokes. Thoroughly wipe off all surfaces with a clean, soft cloth. Apply information such as the following:
a second coat of Minwax® Wipe-On Poly and set the piece aside to
dry overnight. WARNING! Removal of old paint by sanding, scraping or other means
may generate dust or fumes that contain lead. Exposure to lead dust
15. The next day, sand all surfaces lightly with 220-grit or finer sandpa- or fumes may cause brain damage or other adverse health effects,
per or very fine (000) steel wool. Thoroughly wipe off the piece with a especially in children or pregnant women. Controlling exposure to lead
soft cloth and apply a third and final coat of Wipe-On Poly. Allow the or other hazardous substances requires the use of proper protective
finish to cure for several days and then you’ll be ready to start stacking equipment, such as properly fitted respirator (NIOSH approved)
the shelves. and proper containment and cleanup. For more information, call the
National Lead Informations Center at 1-800-424-LEAD (in US) or
Alternate Finish contact your local health authority.
16. Before applying Minwax® Water Based Wood Stain to a hardwood
or softwood, apply Minwax® Water Based Pre-Stain Wood Conditioner When using oil-based wood finishing products:
following the directions on the can. After 1 to 5 minutes, wipe off all CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS. Contents
excess conditioner using a clean, lint-free cloth. Wait 15 to 30 minutes, are COMBUSTIBLE. Keep away from heat and open flame. VAPOR
then use 220-grit or finer sandpaper to sand off any “whiskers” raised HARMFUL. Use only with adequate ventilation. To avoid overexposure,
by the conditioner. Dust off the piece and wipe it down with a soft, open windows and doors or use other means to ensure fresh air entry
lint-free cloth. Proceed to staining within 2 hours. during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory protec-
17. Do the staining in two steps, starting on the interior surfaces and tion (NIOSH approved), or leave the area. Avoid contact with eyes and
then moving to the exterior surfaces. Apply the Minwax® Water Based skin. Wash hands after using. Keep container closed when not in use.
Wood Stain you’ve chosen to the interior surfaces using either a nylon/ Do not transfer contents to other containers for storage.
polyester brush or a soft cloth. Allow stain to penetrate no longer than
3 minutes. While stain is still wet, wipe off all excess with a clean cloth FIRST AID: In case of eye contact, flush thoroughly with large amounts
that’s been lightly dampened with stain. To achieve a deeper color, you of water for 15 minutes and get medical attention. For skin contact,
may apply a second coat after 4 to 6 hours, repeating the application wash thoroughly with soap and water. In case of respiratory difficulty,
directions for the first coat. Allow the piece to dry overnight before provide fresh air and call physician. If swallowed, do not induce vomit-
applying the protective clear finish. ing. Call Poison Control Center, hospital emergency room, or physician
immediately.
Woodworker’s Tip: Minwax® Water Based Wood Stain is NOTICE: Reports have associated repeated and prolonged occupa-
available in 50 custom-mixed colors and a White Wash Pickling tional exposure to solvents with permanent brain and nervous system
Stain. This means that you are not limited to just traditional damage. Intentional misuse by deliberately concentrating and inhaling
wood colors (pine,oak, walnut, etc.). Instead, you can pick and contents may be harmful or fatal.
apply a color to complement the décor of the room in which
the shelves will be.
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WARNING: This product contains a chemical known to the

State of California to cause cancer and birth defects or other
reproductive harm.
DO NOT TAKE INTERNALLY. KEEP OUT OF REACH
OF CHILDREN.

When using water-based wood finishing products:

CAUTIONS: Use Only With Adequate Ventilation. To avoid overexpo-
sure, open windows and doors or use other means to ensure fresh air
entry during application and drying. If you experience eye watering,
headaches, or dizziness, increase fresh air, or wear respiratory protec-
tion (NIOSH approved), or leave the area. Avoid contact with eyes and
skin. Wash hands after using. Keep container closed when not in use.
Do not transfer contents to other containers for storage.

FIRST AID: In case of eye contact, flush thoroughly with large amounts
of water. Get medical attention if irritation persists. If swallowed, get
medical attention immediately.

WARNING: Contains Alkyl propanols, ethylene glycol, n-methyl pyrroli-

done. VAPOR HARMFUL. Use only with adequate ventilation. To avoid
overexposure, open windows and doors or use other means to ensure
fresh air entry during application and drying. If you experience eye
watering, headaches, or dizziness, increase fresh air, or wear respira-
tory protection (NIOSH approved), or leave the area. Avoid contact with
eyes and skin. Wash hands after using. Keep container closed when not
in use. Do not transfer contents to other containers for storage.

DO NOT TAKE INTERNALLY.

FIRST AID: In case of eye contact, flush thoroughly with large amounts
of water for 15 minutes and get medical attention. For skin contact,
wash thoroughly with soap and water. In case of respiratory difficulty,
provide fresh air and call physician. If swallowed, call Poison Control
Center, hospital emergency room, or physician immediately.

DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.

Contains solvents which can cause permanent brain and nervous
system damage. Intentional misuse by deliberately concentrating
and inhaling contents may be harmful or fatal.
WARNING: This product contains a chemical known to the
State of California to cause cancer and birth defects or other
reproductive harm.
KEEP OUT OF REACH OF CHILDREN.

SAFE DISPOSAL OF RAGS AND WASTE.

Please be mindful of the safe way to dispose of rags and other waste.
Rags, steel wool and other waste products soaked with oil finishes or
solvents may spontaneously catch fire if improperly discarded. Place
rags, steel wool and other waste immediately after use in a water-filled
metal container. Tightly seal and dispose of the waste materials in
accordance with local trash removal regulations. Be sure to keep the This project was adapted with permission from The Family
waste out of reach of children. Handyman magazine, Home Services Publications, Inc.,
an affiliate of Reader’s Digest Association, Inc., Suite 700, 2915
Commers Drive, Eagan, MN 55121. ©Copyright 2004. All rights
reserved. For subscriptions call toll-free: 1-800-666-3111.

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FIG 1. SHELVES DETAILS

1" X 4"X 84" FIGURE B

FIGURE A UPRIGHT TOP OF UPRIGHT
MODULAR SHELF ASSEMBLY
21/32"

CLEAT L
1" X 4" X 141/2"
F
K 83/8"
1"X 3" 1"X 3"
10-DEGREE
ANGLE
G SHELF A
33/8"
43/8"

H SHELF B
53/4" 63/4"
84" CLEAT M
1" X 4" X113/4" 113/4"

I
SHELF C
8 3/16"
9 3/16" M

J
SHELF D
10 5/8" O
115/8"
301/2"

SHELF E
14"
13"

CUT CLEAT ENDS CLEAT N

AT 10 DEGREES 1" X 4" X 10"

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FIG 2. APPLYING THE OAK

EDGE-BANDING VENEER

SHELF FRONT

OAK EDGE-BANDING
FIG 3. GLUE AND NAIL CLEATS
VENEER
AIR-POWERED
BRAD NAILER

CARPENTER’S
GLUE

FIG 4. FINAL ASSEMBLY

SPACER

CLEAT

11/4" BRADS

CLAMPS

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