Classic Storage Wall System Bridge

Submitted by Anonymous (not verified) on Wed, 01/27/2010 - 07:50
Difficulty
Beginner
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About Project

A bridge over your media station can give your storage a built in look and quality. But bridges can often be very expensive and not fit just right. With this simple plan that works with the rest of the Classic Media Storage Collection, you can build your own bridge, fit just perfect for your own tv, without spending a bundle.

Dimensions
62" Wide x 16" Tall x 17" Deep (fits over the Classic Wide Media Console)

Preparation

Shopping List

1/2 Sheet of 3/4″ MDF or Plywood, cut into 16 1/2″ Strips, 8′ long
3 – 1×2
1- 1×3 (you will only need 60″)
at least 62″ of 2 1/2″ high moulding

Common Materials
1 1/4 inch screws
2 inch screws
120 grit sandpaper
primer
wood conditioner
paint
paint brush
Cut List

A) 2 – 1×16 @ 13 1/4” (Sides)
B) 1- 1×16 @ 62” (Top)
C) 1 – 1×16 @ 60 1/2″ (Bottom)
D) 1 – 1×16 @ 12 1/2″ (Centers)
E) 4 – 1×2 @ 14″ (Side Trim)
E) 1 – 1×3 @ 59″ (Front Top Trim)
F) 3 – 1×2 @ 59″ (Back Top and Bottom Trim)
Crown Moulding, 2 1/2″ overall height, 62″ Long

Tools
Tape Measure
Speed Square
Pencil
Safety Glasses
Hearing Protection
Kreg Jig
Drill
Circular Saw
Brad Nailer
Power Sander
General Instructions

Cut your 3/4″ Plywood or MDF into strips 15 1/2″ wide by 8′ long. These strips become 1×16 boards. Make your longer cuts first, and then your shorter cuts from the scraps.
Work on a clean level surface. You can fasten with nails or screws, depending on your tools and the use of this piece. Screws will hold better, nails are easier. My general rule is screw anything that will be “used” like chairs and benches, and nail sedentary pieces like bookcases and hutches. I will leave this up to you. If you are screwing, make sure you predrill and countersink your screws. If you are using MDF, avoid fastening within 1″ of the edge of the MDF. Do not use wood screws on MDF. Wood screws do not have a straight shaft and will split your MDF. I have had luck with drywall screws (after all, drywall is very similar to MDF). Make sure you predrill the entire distance of the screws. It’s going to screeech, so wear hearing protection. And glue, glue, glue.

My favorite option is to screw the “box” together, and then use finish nails to add the frame. That way the frame does not have blemishes, but the piece is built sturdy.

Make sure you take a square of the project after each step. Measure and mark out any joints before fastening. Be safe, have fun.

Instructions

Step 1

Wood Composition. The above diagram shows the composition of the different pieces. The “box” is made of 3/4″ plywood or MDF, the trim is mostly 1x2s and a 1×3 boards (pine or MDF for paint grade, hardwood to match A1 plywood for staining). The crown moulding can also be MDF or pine for painting, but should match the A1 plywood for staining.

Step 2

Build the box. Begin by attaching the centers, shown in pink, to the top. Then attach the sides to the top. Finally attach the bottom to the sides and the centers. Use the measurements above to guild you. You should use the 2″ fasteners and glue.

Step 3

Side Trim. Trim the sides, as shown above. Keep outside edges flush. Make sure you fasten the side trim to the top and bottom, and not just the sides. Make sure the bridge is square before attaching. Use the 2″ fasteners.

Step 4

Top, Front and Back, and Bottom Trims. Attach the 1×3 top trim, shown in blue, to the top, as shown above. Then fasten the remaining trim pieces to the back top and the bottom, in green. Keep outside edges flush. Make sure you fasten to the centers too.

Step 5

Finishing Instructions
Preparation Instructions
Fill any nail holes with wood putty and sand and finish as desired. If you are staining and used A1 plywood, you will need to apply edge banding to any exposed plywood edges. This is easy to do, and more information is available in the HOW-TO section under Choosing your Wood. You will need to attach the bridge to the hutch sides for final installation.

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