MyFurniture #1 - How To: a (unique) Shelving Unit for My Living Room

In this project, I am showing you my journey through my first DIY furniture build, a shelving unit. I will begin by showing you from where I got the inspiration (and courage), the process of designing, making and assembling this shelving unit, and how I ended up being really proud of the outcome (and myself).

You can watch the attached video, or if you prefer you can go through this Instructable. Both options should be rather similar. Steps as it follows:

1. A bit of background and motivation
2. Design requirements
3. Concept design and modelling in Fusion360
4. 'Some' woodworking
5. Final assembly: the master piece!
6. What can be improves: tips and tricks!

I hope you enjoy it!

Javito

In the attached files, you will find a spreadsheet with the project file (ShelvingUnitProjectFile) and it contains 3 different tabs:

• Bill of Materials (BoM): where you will find the cost of producing one shelving unit, tools needed and a cost comparison between the shelving unit that was advertised and my DIY alternative.
• Wood breakdown: the idea here was to estimate how much wood is needed for this particular unit, having in mind that I wanted to use most of it, leaving as little remaining as possible.
• Project breakdown: this is a task-based breakdown. I really like the fact of writing what needs to be done in order to achieve your goal, estimated and real time line too (not on this spreadsheet).

About the CAD model and drawings:

• You can download all files (CAD, drawings, BoM) from here.
• You can have access to the latest CAD model in Fusion360 here.
• You can have access to the latest drawings in Fusion 360 here.

This part is easy. My partner found a shelving unit that was offered in an online store that happened to have a branch nearby (smart move from her). Click here for more information or check the corresponding picture.

We went to the shop to check it out and it felt so flimsy, made of thin-squared steel beams for the structure, fake wood for the shelves and you had to attach it to the wall! I did not really like the idea and I could see that "thing" getting rusty in no time. But the design layout was something.

And yes, it happened again, my imagination started working out the same idea but using "better" materials, with conventional tools. And without even checking if I could make it possible, I ended up telling her that I could create the same, with our desired measurements, with REAL wood and cheaper (I am going to regret that). I took the challenge...my first piece of furniture!

Once more, I fell into a black hole. Actually, it is always the same one. I am sure you know what I am talking about.

This shelving unit must comply with the following requirements:

1. Very important one: it cannot collapse. In other words, the design must be robust, without requiring other means of added support (e.g. screws to the wall).
2. The design proportions (dimensions) must look pleasant. If it is too tall/small, it will look weird and I will no longer be a 'piece of art'.
3. I hate screws, especially when you can see them. In this design, I will do my best to keep them away from my sight, using the least amount of them, which brings me to the next bullet point.
4. I need to design some kind of 'easy to make' joinery, so I can attach beams that define the height, length and depth of the shelving unit at the same point.
5. I would like to avoid any kind of glue and/or dowel pins. These things for another day.
6. This shelving unit must be easy to assemble/disassemble with only ONE (conventional) tool, a screw driver. This also includes how easy it is to handle and transport it to another room/house.

Concept design: the challenge

I needed to have a proof of concept, a proof that this shelving unit is actually manufacturable. Here, my big (personal) challenge was the fact of joining three different squared-profile beams coming from three different directions (depth, length and height) with only two screws and using some kind of joinery that could be produced with a table saw and/or a router tool. Of course, the screws always from the sides, so they cannot be seen if someone is standing in front of such a (future) 'piece of art'.

It would be nice to see people looking at it and thinking that everything is glued, but not. It is funny, because I could see the shelving unit already finished and standing in my living room. However, I had NOTHING just yet.

Do you think I managed to find a solution? Well, I would have been writing this Instructable even if I didn't. At least you would have seen someone doing something that should not be done, hence less time wasted for you. But, I did find a solution that requires only 2 screws to join 3 beams coming from three different orthogonal directions.

I am not showing you a sketch, because a 3D-model will be much better in order to understand what I was about to build!

CAD modelling: the other challenge

I used to have a student license for SolidWorks and absolutely adored that program. Why? It was simple. I am no longer student, so kaput. I currently use Siemens NX at work and I call it the click-click program because you have a pop-up window or a wizard for every single operation you want to perform. The above options are unaffordable for people like me, so I went for something more 'neutral', Fusion 360.

Fusion 360 is....Fusion 360. This program lets me do my job and it is affordable. I am still learning its functionalities, but so far it is a nice-to-have piece of software if compared to other options.

Unfortunately, my license for SolidWorks expired and that is why you will see pictures in which I use a different software or the drawings look a different. No worries, everything was made from scratch (again) in Fusion360.

Coming back to the project...

First, I wanted to find out what components would be the cost drivers of my build, so I went to several local stores in order to check the dimensions, purchase quantity and cost of the different types of wood advertised. I also checked screws and supports for the shelves. The most expensive components were the wooden panels (made of pine) needed for the shelves. That I kept in mind.

After my visit, I concluded that in my case I would like to use:

• Square-profile beams of 43x43mm since there will be less chance of making mistakes later. Length-wise, I chose 2.1m, easy to bring them in my car and to manage during the cutting process.
• Rectangular panels of 1150x250x18mm for the shelves. Other sizes offered where either too big or too small, so I literally had no choice.
• 90deg galvanised steel supports for the shelves.

That was enough to start sketching in Fusion 360. My design would be based on then most expensive component, so I would use them all! In this case, the wooden panels. But there was something else going on here...

I was planning to share this build with you, but how do I know that you have the same wood available in your area? This is a common problem I see in many DIY builds. The materials used are so specific that you end up building the same from scratch in order to adjust the build to the availability in your area. This does not make sense. I wanted to make it easier for you, so you don't have to spend the same time (or even more) doing what I already did!

I decided to create the CAD model based on expressions, so you modify a few parameters and you get your build in minutes, with drawings included! Now, that is a bargain!

You will find tether model and corresponding drawings attached to this Instructable. Please bear in mind that if the dimensions you insert don't make sense, Fusion 360 will complain. In other words, this design can be fine-tuned in order to fit your needs but don't change the layout. Unfortunately, I did not have time to define conditions in Fusion 360 (if that is possible).

At this point, I suggest you watch the video for a more detailed explanation.

One BIG question: how do I manufacture and assemble this thing?

Exactly. In the CAD program, everything holds up together pretty well but I needed to foresee the manufacturing/assembly process and if I would need extra tooling.

For making the pockets in the structure I decided to use the table saw, but I needed to develop some kind of platform that would allow me to keep the wood in place at a certain height while making the pockets, also allowing me to repeat the same process, achieving the same results. Yes, I needed a cross-cut sled. A simple and reliable one that I could develop and calibrate quickly. Check out Youtube for ideas!

Now imagine me in front of my laptop, happy because I know how to create the pockets in a reliable way. However, I also needed to figure out a way of checking how everything needs to be assembled (the final goal), references used and so on. I decided to use the animation tool in Fusion360, so I could foresee if additional tools would be required in order to successfully assemble this beauty!

You can download the CAD model from the 'Supplies' section

Last but not least: drawings

Yes, you need them. Why? A total of 9 different beams and 2 panels will be necessary. Being organised at this point is crucial and having a piece of paper containing all relevant information for each of the beams/panels is just a go-go. No headaches, I promise!

As for the assembly part, labelling each wooden beam is also important, because we are humans and we make mistakes. Let's be honest, my first shelving unit won't be perfect and I will end up cherry-picking, hence the labelling. In addition, it helps when moving the furniture (e.g. too a different place).

You can download the drawings from the 'Supplies' section

But first, the cross-cut sled. Check the pictures/video!

Here is the process I followed in order to produce each of the beams:

1. Measure and cut. Avoid measuring everything and then cutting. Mostly probably you will forget about adding ~3mm that disappear because of the saw blade. If you measure and then cut, you will be able to follow the drawings perfectly.
2. Keep it tidy, keep it cool! Yes, you will see that your working area is full of wooden beams all of the sudden. Sort them in different spaces and place the drawing on top in order to avoid confusion. Only one drawing at the time!
3. Measure and cut (again!). Now, the pockets. Be careful with the orientation of the pockets within a beam, set the blade to the specified height and test the resulting cut in a scrap piece of wood! Satisfied? Let's continue with the real one and don't change the height until you finish! Making the pockets is easy and I tried removing all the wood using the sawing machine and I found it to be very, very time-consuming. Since I was using pine (soft wood), I decided to make a maximum of 10 cuts per pocket, removing the remaining with my fingers (pretty easy) and finishing it with a chisel (great fellow).
4. Take breaks and keep calm. Otherwise you will have to repeat this again.

This 'simple' process took me a few days, but I enjoyed every second. It just worked straight form the paper. The result was pretty satisfactory. Check the pictures!

I decided to go for a first assembly without even sanding and giving a few layers of 'something'. This is because we didn't really know if we wanted to stain, oil, wax or lacquer the wood. Therefore, I did not do anything for the time being, just to see how it would look in my living room. I still think this was a safe move.

I followed the process I defined in the animation, step-by-step. So, I am not going to repeat myself! Check the pictures and/or watch!

The (un)finished product looks majestic!

Conclusion

Does this shelving unit cost less than the one advertised? Definitely no. However, this is a unique piece of furniture that will be standing on your living room (or elsewhere), made by yourself with real wood, it does not need to be attached to the wall and I believe the weight per shelve is more than 8kg. To be tested.

In addition, it has been a rewarding experience for me, since I have learned something new and I also used skills I already had! Definitely a win-win situation!

Tips for you (or mistakes I made)

• I cut the pockets +1mm wider than what they should have been and I lost structural strength. I did this on purpose since I was not really sure I would be able to achieve the accuracy I was aiming for. It turned out that I was wrong (good for me). Try to make the pockets as tight as you can. It is always better to end up removing some extra material rather than having to buy more wood, starting from the beginning.
• Measure/level everything and keep your drawings always close for verification
• Be careful if you need a very long shelving unit. Keep in mind that the horizontal beams should be able to stand the structural weight, otherwise you will appreciate sagging.
• Make sure you use straight beams or you will face some good challenges with twisted/cracked wood beams. I chose pine as it was affordable, but it is a soft wood and therefore I ended up having sag issues because of the structure itself and beams not being very straight. It was ~3mm in the middle with respect to the sides, empty shelving unit and ~4mm loaded as in the picture. I relied on a "perfect" wood beam, which is not true.

Another version is coming soon!

I am thinking of uploading a new version:

• My partner did not really like the way I ended the shelves (see picture), so I am planning to 'finish' them the same was as the sides of the structure.
• I would like to add two more legs to account for sagging. For this, I will extend the vertical beams that are located almost in the middle of the unit. This feature is ideal if you are planning to place have things (e.g. crockery)

A few add-ons to make this shelving unit 'better':

• I also have a rather visible extension lead that I think would be nice to hide somehow, with proper wiring routing.
• I would lie to add wireless charging capabilities to one of the shelves. This must be amazing.
• Lastly, adding some LED strips that could work as ambiance light, with colour temperature and tone adjustment.

I hope you enjoyed! Now its time for you to make this build unique!