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You can use that same jig for the bottom arched cutout. Simply drill another hole 3 1/8″ away from your nail. Set the nail as close to the center of the bottom edge as possible and mark the cutout arch. Or, mark the arch with a traditional compass.
Now use your jigsaw to cut as close to the lines as possible, and use a rasp and sandpaper to clean up the cuts. If you keep the pieces clamped together during this process, you should end up with nearly identical arches. If you’re not confident in your jigsaw skills, practice making curved cuts on some scrap pieces before moving on to the real thing. Now cut the shelves to length.
Set up your pocket-hole jig for 3/4″-thick material. Mark the placement for three pocket holes on each end of each shelf, two of them 3/4″ from each long edge, and one in the center of the end. Drill the holes. (For more pocket-hole instruction, see the December 2006 project or the PDF manual.)
Cut the back supports to length, and sand all pieces to #150-grit before assembly (#120 if you’re planning to paint).
Now you’re ready for assembly, and the second trick we promised. Lay one side flat on your bench and mark the location of the top shelf at either side. You may not be able to line up the shelf with your marks because of cupping in the wide board; that’s where the trick comes in. Position the back support (or any straight piece of scrap) along the bowed side of the shelf, if there is one, and use clamps to bring the edges of the shelf flat to the support or straight scrap. Slide the clamped unit to the layout lines, hold or clamp it in place then use screws to attach. This trick will work to pull the bow from any of the shelves.
Attach all three shelves to both sides, straightening the pieces where necessary.
Now lay the assembly face down, line up the support with the top of your top shelf. Drill countersunk holes at the top shelf, at the bottom shelf, and at the inside edge where the support meets the middle shelf. Be sure to hold your drill at 90° to the sides; because you’re drilling into 3/4″ stock, you could easily drill through the side if you’re not careful.
Attach the uprights with #8 x 1-1/4″ screws (rubbing the threads on some wax will help them seat more easily). Pay particular attention at the top and bottom as the stock can easily split. If it does crack, stop your drill immediately – but don’t panic. Just back the screw out a tiny bit, and the split will close up. Finish the shelves with two coats of wiping varnish. PW
Megan is managing editor and Glen is senior editor of Popular Woodworking.
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