Rack with Key Box

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring tape (≥5m)

  Used for measuring each part

• ✓

  Pencil and carpenter's square

  For marking lines and confirming right angles

• ✓

  Saw

  Home center cutting service recommended

• ✓

  Electric driver

  Impact driver enhances work efficiency

• ✓

  Sandpaper

  Prepare #120 and #240 grits

• ✓

  Level

  Essential for checking horizontality during assembly

• ✓

  Clamps (2 or more)

  Used for temporary fixing during joining

• ✓

  Brush and paint tray

  Used for oil or varnish finishing

Materials

Build steps

1. 1

   Final Check of Materials and Tools

   ≈ 15 min

   Prepare two side boards of SPF lumber 1x8 (19×200×600mm), six shelf boards (19×200×500mm), one 4mm plywood back board (500×600mm), sixteen 38mm coarse-thread screws, and four 50mm L-shaped brackets. Gather the tools: electric driver, saw, measuring tape, carpenter's square, #120/#240 sandpaper, level, two F-clamps, brush and paint tray, tackers or small nails.

   Measure

   W 500 mm

   MeasureSTEP 1 / 20

   Tip

   • SPF lumber tends to warp. Inspect each board visually at purchase, selecting those with warp less than 1mm.
   • L-shaped brackets and screws are critical for preventing overturning. Do not omit them under any circumstances.

   Watch out

   • Check each SPF board for warp, cracks, and knots before purchase. Using boards with warp over 1mm will cause shelf boards to distort.
   • The 4mm plywood back board is thin and prone to break when moved. Store it upright immediately after cutting.
2. 2

   Securing the Work Area

   ≈ 10 min

   Ensure a workspace where the 600mm-tall bookshelf can be stood upright. A room with 2200mm ceiling height or more, and a floor space of about 1500×1200mm is sufficient. Lay a blue sheet and support long materials on two saw horses.

   Inspect

   No wobble ✓

   InspectSTEP 2 / 20

   Tip

   • Assemble the bookshelf lying on the floor and raise it in the final step. This works even in narrow rooms.

   Watch out

   • It is difficult for one person to stand the assembled bookshelf upright. Two people are recommended for safety.
   • If ceiling height is less than 2000mm, the bookshelf may hit the ceiling when raised. Confirm beforehand.
3. 3

   Creating the Cut List and Requesting Cuts

   ≈ 20 min

   Submit a cutting list to the home center for two side boards (600mm), six shelf boards (500mm), and one back board (500×500mm). If cutting yourself, support 600mm lengths on two saw horses and make cuts by pulling the saw. Aim for a cut accuracy within ±2mm.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 20

   Tip

   • Cutting fees range from 30-50 yen per cut. Full cutting service costs about 1000 yen, reducing cutting time from 30 minutes to immediate.
   • Cut the six shelf boards bundled together for best accuracy as they share the same dimensions.

   Watch out

   • 19mm thick SPF lumber easily warps even with straight cuts. Use a guide to cut straight.
   • 4mm plywood is soft and will bend and distort during cutting unless supported underneath.
4. 4

   Sanding All Parts (#120 → #240)

   ≈ 40 min

   Sand all parts starting with #120 grit followed by #240 grit. Pay special attention to the shelf support surfaces on side boards, the top and bottom of shelf boards, and cut ends (end grain). Rounding the edges of shelves where hands touch improves handling. Vacuum completely to remove wood dust after sanding.

   Sand

   #120

   SandSTEP 4 / 20

   Tip

   • Smooth surfaces on shelf boards enable books to be inserted and removed easily.
   • Cut ends have raised fibers that require careful sanding, starting with #120 grit.

   Watch out

   • SPF lumber is soft; over-sanding can change dimensions. Use #120 mainly and #240 only for finishing.
   • Rounding edges excessively results in a bulky look; limit rounding to approximately a 2mm radius.
5. 5

   Marking Shelf Positions on Side Boards

   ≈ 15 min

   Align the two side boards and mark shelf positions with pencil for six shelf levels. Shelf intervals from bottom are 300mm each (total 1800mm for 6 shelves), or design with wider spacing at the top for display. Mark both side boards simultaneously ensuring exact matching positions.

   Mark a line

   Use a try square

   MarkSTEP 5 / 20

   Tip

   • Clamp the two side boards tightly together before marking to ensure shelf positions perfectly align left and right.
   • Use heights to guide spacing such as A4 size (297mm high), A5 (210mm), and paperback size (150mm).

   Watch out

   • If shelf positions do not align, shelf boards will be inserted crookedly. Mark both boards together while clamped.
   • Do not forget the 19mm shelf thickness when calculating space, or gaps will be too narrow in reality.
6. 6

   Preparing Pilot Holes

   ≈ 20 min

   Drill 3mm diameter pilot holes at the marked positions. Drill through the outside of the side board toward the shelf board edge. Use masking tape on the drill bit as a depth guide. Drill through the 19mm side board plus 10mm into the shelf board (total 29mm depth).

   Drill a hole

   下穴 φ3.5mm

   DrillSTEP 6 / 20

   Tip

   • 3mm pilot hole diameter is about 70% of the 4.2mm coarse-thread screw shaft diameter, effectively preventing wood splitting.
   • Each shelf needs two pilot holes on each side board = 6 shelves × 4 holes = 24 holes total. Double-check all are drilled.

   Watch out

   • If pilot holes are too shallow, screws will not enter fully. Drill slightly deeper for safety.
   • Avoid drilling all the way through the shelf board by using tape as a depth stop.
7. 7

   Temporarily Fixing Shelf Boards to One Side Board

   ≈ 20 min

   Lay one side board flat on the floor, stand six shelf boards on it at the marked positions, clamp them temporarily with F-clamps. Check with a carpenter's square that each shelf is perpendicular to the side board. Visual check where the square cannot fit.

   Build the frame

   Check for square

   AssembleSTEP 7 / 20

   Tip

   • Stand shelf boards from the bottom shelf up for better stability.
   • Use one clamp per shelf board if possible; six clamps make the process easier, or work sequentially with two clamps.

   Watch out

   • Fixing with incorrect right angles causes overall skew (parallelogram shape). Always check with carpenter's square.
   • If shelf boards protrude beyond side board edges, the back board will not fit later.
8. 8

   Screwing One Side Board

   ≈ 15 min

   Drive 38mm coarse-thread screws through pilot holes from the outside of the side board into each shelf board edge, two screws per shelf level (12 screws total). Screw heads should be flush or recessed 0.5mm below the surface. Use moderate torque on the impact driver and tighten the last 1/4 turn by hand.

   Drive screws

   コーススレッド 51mm

   ScrewSTEP 8 / 20

   Tip

   • Offset the two screws slightly up and down to increase withdrawal strength.
   • If screw holes are visible, they can later be filled and hidden with wooden dowels (optional).

   Watch out

   • Over-tightening screws in 19mm SPF lumber cuts can crack end grain. Use medium torque.
   • If screws enter at an angle and protrude through, remove, fill hole with wood filler, and re-screw elsewhere.
9. 9

   Preparing to Attach the Opposite Side Board

   ≈ 15 min

   Stand the assembly with one side board fixed and hold the second side board on the opposite side. Align the shelf ends to the marked positions on the opposite side board and clamp temporarily. Confirm verticality and right angles with the assembly upright.

   Build the frame

   Check for square

   AssembleSTEP 9 / 20

   Tip

   • Two-person work is recommended: one holds, another clamps for accuracy.
   • Opposite side board should have pre-marked shelf positions; no need to redraw.

   Watch out

   • Working alone risks shelf boards falling off and damaging the floor. Use two people or brace the assembly against a wall.
10. 10

    Screwing the Opposite Side Board

    ≈ 15 min

    Drive 38mm coarse-thread screws through pilot holes from outside the opposite side board into each shelf board edge, two screws per shelf level (12 screws total). This fixes both side boards and six shelf boards, completing the main structure.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 10 / 20

    Tip

    • After fixing both sides, check each shelf's level with a level. Loosen and adjust if one shelf is tilted.

    Watch out

    • Screwing both sides simultaneously can cause distortions. Completely screw one side before the other.
11. 11

    Overall Level and Diagonal Check

    ≈ 15 min

    Place the assembled bookshelf on the floor and check each shelf's level with a level. Measure diagonals (top-left to bottom-right and top-right to bottom-left) from the front; difference should be within 5mm. Correct distortions by loosening clamps and adjusting, then add screws to fix.

    Check level

    Level ✓

    LevelSTEP 11 / 20

    Tip

    • Diagonal differences greater than 5mm indicate a parallelogram shape. Correct before installing back board.
    • Back board adds rigidity; fix distortions before attaching it.

    Watch out

    • Shelf sagging (center lower than edges) worsens with book weight. With 600mm shelf length design this is acceptable; longer shelves above 1000mm require reinforcement.
12. 12

    Preparing to Attach the Back Board

    ≈ 10 min

    Place the 4mm plywood back board (500×500mm) against the back of the main body. Align all corners and check diagonal match with the main frame. Attach the back board lightly with masking tape as temporary fix. Attaching the back board can also correct slight distortions.

    Build the frame

    Check for square

    AssembleSTEP 12 / 20

    Tip

    • Back board is a critical structural part that prevents distortion. Avoid installing it skewed or slanted.
    • 4mm plywood can be easily fixed with a tacker. Use pilot holes if attaching with small nails.

    Watch out

    • If the back board is larger, trim any protruding parts. If smaller, keep an even gap within 5mm around edges.
13. 13

    Fixing the Back Board with a Tacker

    ≈ 20 min

    Attach the back board to side boards and shelf boards with a tacker (15mm staples) or small nails. Fix every 100-150mm around the entire perimeter and also along shelf positions. Start at corners and fix along diagonals to avoid distortion.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 13 / 20

    Tip

    • Tackers cost 1500-2500 yen at home centers and are faster than nails; worthwhile investment for bookshelf assembly.
    • Mark shelf positions on the back board with pencil before fixing to avoid missed spots.

    Watch out

    • Staples penetrating inside may damage books. Use 15mm staples appropriate for 19mm thickness.
    • Fix along all four edges and shelf positions to prevent back board from lifting under load.
14. 14

    Preparing to Attach L-shaped Brackets

    ≈ 15 min

    Attach four 50mm L-shaped brackets: two on left and right at the upper rear. One side attaches to the bookshelf top edge; the other side secures to the wall. Use a stud sensor to locate wall studs beforehand.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 14 / 20

    Tip

    • Toy store or 100 yen store stud sensors have low accuracy. Prefer home center sensors for 1000-2000 yen.
    • Studs usually spaced at 455mm; after locating one, estimate the others easily.

    Watch out

    • Fixing into drywall only is ineffective for overturn prevention. Always screw into studs.
    • Adjust bracket positions left/right to align screw holes with center of studs.
15. 15

    Attaching L-shaped Brackets to Bookshelf

    ≈ 10 min

    Fix the four L-shaped brackets to the outside upper side boards of the bookshelf. Use 38mm coarse-thread screws in the bracket's screw holes. Fix brackets flush or with less than 5mm gap to side board, oriented so the bent part faces the wall and the screw holes face the bookshelf.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 15 / 20

    Tip

    • Ensure bracket orientation with bend toward wall and screw holes facing bookshelf side.

    Watch out

    • Incorrect bracket angle creates gaps between bracket and wall, reducing effectiveness. Use level to verify installation.
16. 16

    Setting Up the Bookshelf and Wall Attachment

    ≈ 20 min

    With two people, carry the bookshelf to its final position. Place it flush against the wall. Using 45-50mm coarse-thread screws (included or separate), fix all four brackets through wall-side holes into wall studs. Complete all four fixings to prevent overturning.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 16 / 20

    Tip

    • 38mm screws are too short for wall. Use 45-50mm screws that reach wall studs.
    • Wall fixing is the most important step. Cutting corners risks injury or death during earthquakes.

    Watch out

    • Drywall anchors alone do not provide sufficient strength. Always screw into studs.
    • If there is a gap exceeding 5mm between wall and bookshelf, insert shims before fixing. Loose brackets do not prevent overturning.
17. 17

    Cleaning Before Painting

    ≈ 10 min

    Thoroughly clean the entire bookshelf with a vacuum and dry cloth to remove wood dust, oils, and fingerprints. Quality of cleaning before painting heavily influences the finish. Optionally mask the plywood back board since it absorbs finish quickly.

    Inspect

    No wobble ✓

    InspectSTEP 17 / 20

    Tip

    • Clean wiping before finish should follow this order: dry wipe → wet wipe → dry wipe again for perfect cleanliness.

    Watch out

    • Residual wood dust causes rough paint surfaces. Use lighting to inspect.
18. 18

    Applying Oil Stain (First Coat)

    ≈ 40 min

    Apply oil stain (such as Watco Oil or Kinura) evenly using a brush. Sequence: outside of side boards → shelf board top surfaces → shelf board undersides → back board. After 10-15 minutes, wipe off excess with a dry cloth. Use 60-70% of the total amount for the first coat as absorption is high.

    Paint

    Watco oil / varnish

    PaintSTEP 18 / 20

    Tip

    • Follow 'apply → wait 10-15 minutes → wipe off' procedure; not wiping off leaves sticky residue.
    • Brush width of 30-50mm is ideal for bookshelf parts; too wide or too narrow is inefficient.

    Watch out

    • Not wiping off excess oil leaves stickiness for over a week.
    • Plywood back board absorbs quickly and is prone to unevenness; apply thinly and wipe carefully.
19. 19

    Applying Oil Stain (Second Coat)

    ≈ 25 min

    After 24 hours drying from the first coat, apply a second coat using one-third to one-half the first coat's amount. Remember to wipe off excess as before. Two coats deepen color and enhance protection. Allow 24-48 hours for full drying.

    Paint

    Watco oil / varnish

    PaintSTEP 19 / 20

    Tip

    • Second coat corrects color unevenness from the first coat. Apply a thin, uniform layer.
    • Add a third coat if a darker color is desired.

    Watch out

    • Forgetting to wipe off after the second coat causes uneven finish.
    • During drying, keep indoors protected from dust and insects.
20. 20

    Completion, Use, and Inspection

    ≈ 15 min

    After complete drying (48 hours), arrange books and begin use. Place heavy books on lower shelves and lighter ones on upper shelves for stability. After one week of use, recheck screw tightness and L-bracket fixings, retightening if needed.

    Done!

    Done — nice work!

    DoneSTEP 20 / 20

    Tip

    • Concentrate heavy books (like encyclopedias) on the bottom two shelves. Upper shelves can hold paperback and regular books to reduce weight.
    • Reapply oil every 3-5 years to revive gloss and protective effects.

    Watch out

    • Placing books immediately after finishing risks oil transferring to them. Always allow at least 48 hours to dry.
    • Books absorb moisture; use dehumidifiers during rainy season. Moisture can warp the bookshelf.

Warnings

• ⚠️Always drill pilot holes before driving screws to prevent wood splitting.

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