It's quicker to grab one of the test pieces from Step 3 to mark the notches in the shelf corners. Make certain to line up the tops of the shelf standards with the tops of your verticals…this is especially critical if you opt for verticals that are taller than your shelf standards (having empty space at the bottom of the dados is less important than having empty space at the top - and it's important that all four shelf standards line up once they're in your locker).Ī half dozen nails per shelf standard should be plenty to hold the standards in place. Use the needle nose pliers to hold the tiny nails in place as you install the shelf standards in the dados. Tap each nail's pointy end a few times with a hammer to blunt the tip (which also shortens the nail just enough to prevent it from sticking out the back of the vertical pieces). Simply grip each nail one at a time with needle nose pliers so that the nail's head is flat on a firm surface and the nail's pointy end is sticking up. It's much easier to fix this before using the nails than to deal with it after they're in place. They will protrude from the back of the verticals just enough to scratch up the locker. The tiny nails that came with my shelf clips are a hair too long. Run both edges of all four verticals through the router table now that you've raised the bit's height. Repeat for the all four verticals before adjusting the router bit's height to the full depth needed for the shelf standards to fit flush (~3/16"). Verify your dado is now as wide as you want (though not yet deep enough)…adjust the router fence as needed so that the shelf standard fits neatly in the dado. Run a test piece over the bit, flip it so the opposite edge is now against the fence (but the same face is still down) and run it again. It will take four passes through the router table for each dado…set the router fence so it just touches one inside edge of your dado and is cutting no more than 1/8" thick per pass. For a 1/2" wide dado, I used a 3/8" dado bit. I like to use a router bit that's narrower than the desired dado but at least a little more than half the final width of the dado. It's not critical that the dados are centered on the vertical pieces but I think it looks cleaner. Adjust your dados as needed so they match (or are slightly oversized) for your shelf standards. Measure your shelf standards for width and thickness in case they don't match the ones I used. This makes the shelves simpler and keeps the finished project looking a little nicer. Routing a 1/2" wide by 3/16" deep dado down the center of each vertical piece will let the shelf standards sit flush with the surface of the verticals.
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