Mid Century Modern Bookshelf – Part 2: How

Project Timeline

Timeline Overview:

Ideation (Weeks 1–3):

• • Explored inspirations, designed three separate CAD files:

    1. A spinal column shelf with movable shelves

    2. An entryway table with kerf-cut corners

    3. Final iteration: a hip-height, mid-century modern inspired bookshelf

• Prototyping (Weeks 3–8):

  • Built cardboard and 3D printed prototypes to test proportions, joinery, and leg designs.

• Material Shopping (Week 8):

  • Researched local lumber yards, ultimately purchasing 1/4” sande birch plywood from Home Depot due to pricing and availability.

• Fabrication (Weeks 8–11):

  • Full construction phase including cutting, joinery, sanding, staining, and assembly.

• Finishing (Week 11):

  • Final staining, polyurethane finishing, and detailed sanding.

• Documentation (Ongoing):

  • Process photos, videos, and reflections collected throughout.

[Image Center: Timeline graphic showing phases with dates (weeks) and arrows connecting stages]

---

Detailed Fabrication Process

Step 1: Material Preparation

I started by ripping the full 4’x8’ sande plywood sheet in half using a track saw, making it more manageable to work with in the BTU Lab. I laid out all my bookshelf components digitally using SketchUp to ensure efficient cuts and minimal waste.

---

Step 2: Panel Cutting

Using the table saw, I cut all major pieces to size, carefully ensuring straight and square cuts.

---

Step 3: Rabbet Joinery

I lowered the table saw blade to about 1/8” height and made multiple passes (four cuts per edge) to form the rabbet joints on the top and bottom panels. After roughing them out, I cleaned the joints with a chisel to get clean, crisp edges.

[Image Center: Photo of cutting rabbet joints on table saw]
[Image Right: Photo of chiseling rabbets clean]

---

Step 4: Dry Fitting

Once the rabbets were ready, I dry-fitted the perimeter pieces (top, bottom, and side walls) to check alignment and fit. I also adjusted the inner wall pieces to match the assembled frame dimensions.

---

Step 5: Leg Fabrication

I laser cut a single template piece for the bookshelf legs. Using the bandsaw, I cut rough outlines proud of the final shape, then flush-trimmed them to perfection using a palm router and a flush-trim bit on a makeshift router table setup.

 

After shaping, I used the palm router again to add a 1/4” roundover fillet to the edges of the legs, giving them a smooth, soft aesthetic typical of mid-century modern furniture.

---

Step 6: Sanding

Sanding was a major part of the process:

• Hand-sanded tricky edges first with 100 grit.

• Orbital sanded flat surfaces progressively:

  • 80 grit → 120 grit → 160 grit.

---

Step 7: Staining

I hand-wiped Varathane Espresso oil-based stain across all surfaces. This took about 2 hours, ensuring full coverage without blotchiness. I let it dry for around 3 hours, doing minor touchups where needed.

---

Step 8: Finishing

After staining, I used a foam brush to apply an oil-based gloss polyurethane coat. I allowed it to dry overnight, then lightly sanded the surface by hand with 600 grit sandpaper for a silky smooth finish.

---

Step 9: Assembly

Final assembly involved:

• Aligning and gluing the perimeter frame using wood glue and clamps.

• Screwing and gluing legs into place.

The final piece came together steadily, and once assembled, I let everything cure fully before moving it into my room.

---

Conclusion and Reflection

Reflecting back, my bookshelf evolved quite a bit from my original idea. I began with grand plans for movable shelves and intricate adjustable parts, but practicality and time constraints forced a simpler, more elegant solution.
The final bookshelf:

• Captures the mid-century modern aesthetic I was aiming for: clean lines, warm tones, rounded details, and smooth tactile finishes.

• Feels solid and functional, even though I didn’t achieve all of my original functionality goals (no sliding shelves or drawers).

What I’m proud of:

• The clean edges and flush-mounted legs make it feel intentional and crafted.

• The stain finish brought the plywood to life, giving it richness despite its affordable materials.

What I would change:

• I wish I had used real hardwood. It would have provided better durability, richer visual depth, and would have made clean edge work easier.

• I also would have spent more time precisely planing and trimming pieces to get flawless joinery.

Future of the Piece:

Today, the bookshelf sits in my bedroom, filled with books, records, and trinkets. Over time, I imagine the look will keep evolving as the contents change—exactly how I originally envisioned it.