Hanger Rack with Hat Hooks

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring Tape (5m or longer)

  Used for measuring all parts.

• ✓

  Pencil and Carpenter's Square

  For marking lines and verifying right angles.

• ✓

  Saw

  Using home center's cutting service is recommended.

• ✓

  Electric Screwdriver

  Impact driver improves work efficiency.

• ✓

  Sandpaper

  Prepare #120 and #240 grit.

• ✓

  Level

  Essential for checking horizontality during assembly.

• ✓

  Clamps (at least 2)

  Used for temporary fastening during joining.

• ✓

  Brush and Paint Tray

  Used for oil and varnish finishing.

Materials

Build steps

1. 1

   Final Check of Materials and Tools

   ≈ 15 min

   Prepare two side boards (SPF lumber 1x10, 19×400×1700mm), six shelf boards (19×400×900mm), one plywood back panel (4mm thick, 900×1700mm), 40 coarse-thread screws 38mm, four 50mm L-brackets. Tools include electric screwdriver, saw, measuring tape, carpenter's square, #120/#240 sandpaper, level, two F-clamps, brush and paint tray, and a tacker or small nails.

   Measure

   W 900 mm

   MeasureSTEP 1 / 20

   Tip

   • SPF lumber tends to warp. Inspect each board visually when purchasing and select boards with warp under 1mm.
   • L-brackets and screws are crucial for tipping prevention and must not be omitted.

   Watch out

   • Check each SPF board for warp, cracks, and knots before purchase. Using boards warped over 1mm causes shelf distortion.
   • The 4mm plywood back panel is thin and easily damaged during handling; stand it upright immediately after cutting.
2. 2

   Securing the Workspace

   ≈ 10 min

   Ensure a workspace where the 1700mm tall bookshelf can be assembled upright. A ceiling height of 2200mm or more and floor space about 1500×1200mm is sufficient. Lay a blue sheet and use two sawhorses to support long materials.

   Inspect

   No wobble ✓

   InspectSTEP 2 / 20

   Tip

   • Assembly is done lying on the floor; standing up the bookshelf should be the final step. This allows work in confined rooms.
   • It is difficult for one person to stand the assembled bookshelf upright. Two persons are recommended for safety.

   Watch out

   • The assembled shelf is difficult to stand up alone; 2-person work is safer.
   • If ceiling height is below 2000mm, the bookshelf may hit the ceiling when standing up; verify beforehand.
3. 3

   Creating Cut List and Ordering Cuts

   ≈ 20 min

   Submit a cut list for two side boards (1700mm), six shelf boards (900mm), and one back panel (900×1700mm) to the home center. If cutting yourself, support 1700mm long stock on two sawhorses and perform pull cuts. Aim for cutting accuracy within ±2mm.

   Cut

   Use the in-store cut service

   CutSTEP 3 / 20

   Tip

   • Cutting cost is about 30-50 yen per cut; total is around 1000 yen and reduces work time from 30 minutes to immediate.
   • Bundle the six shelf boards and cut simultaneously for highest accuracy.

   Watch out

   • 19mm thick SPF is prone to warp even with straight cuts; use a guide to cut straight.
   • 4mm plywood is soft and warps if unsupported from below during cutting.
4. 4

   Sanding All Parts (#120 to #240)

   ≈ 40 min

   Sand all parts starting with #120 grit, then finish with #240. Pay particular attention to shelf support faces on side boards, upper and lower surfaces of shelf boards, and the edges (ends). Rounding shelf edges where hands touch improves usability. Vacuum thoroughly after sanding to remove all dust.

   Sand

   #120

   SandSTEP 4 / 20

   Tip

   • Smooth shelf surfaces facilitate smoother placing and removing of books.
   • Edges expose raised fibers and require careful sanding, starting from #120 grit.

   Watch out

   • SPF lumber is soft; removing too much material distorts dimensions. Use #120 for base sanding and #240 only for finishing.
   • Rounding edges excessively looks bulky; keep a radius around 2mm.
5. 5

   Marking Shelf Positions on Side Boards

   ≈ 15 min

   Place two side boards side by side and use a pencil to mark positions for six shelves. Shelf spacing can be 300mm each from bottom up (total 1800mm) or adjusted as per design for decorative gaps at the top. Align two side boards perfectly and mark simultaneously so shelf positions match exactly on both sides.

   Mark a line

   Use a try square

   MarkSTEP 5 / 20

   Tip

   • Clamp two side boards together before marking to ensure identical shelf positions.
   • Use A4 (297mm), A5 (210mm), and bunkobon size (150mm) books as references for shelf spacing for practical storage.

   Watch out

   • Mismatching shelf positions causes tilted shelf boards; always clamp and mark together.
   • Ignoring the 19mm shelf board thickness in spacing calculations results in narrower actual gaps.
6. 6

   Preparing Pilot Holes

   ≈ 20 min

   Drill 3mm diameter pilot holes at marked positions. Drill from the outside of the side board into the shelf board edge so holes pass through side board (19mm) and enter shelf board about 10mm, total 29mm deep. Use masking tape on the drill bit as depth stopper.

   Drill a hole

   下穴 φ3.5mm

   DrillSTEP 6 / 20

   Tip

   • 3mm pilot hole is 70% diameter of 4.2mm coarse-thread screws, effectively preventing wood splitting.
   • Each shelf requires two pilot holes on both sides (4 holes per shelf ×6 shelves = 24 holes); verify none are missed.

   Watch out

   • Pilot holes that are too shallow prevent screws from fully seating; drill slightly deeper for safety.
   • Avoid drilling through to the opposite side of the shelf by limiting depth with tape.
7. 7

   Temporarily Fixing Shelves to One Side Board

   ≈ 20 min

   Lay one side board flat on the floor and stand the six shelf boards at marked positions. Temporarily clamp using F-type clamps and confirm right angles between side board and shelf with carpenter's square. If the square cannot fit, verify visually.

   Build the frame

   Check for square

   AssembleSTEP 7 / 20

   Tip

   • Installing shelves from bottom up enhances stability during assembly.
   • One clamp per shelf board speeds work but if only two clamps are available, proceed stepwise.

   Watch out

   • Fixing at off-right angles causes the structure to deform into a parallelogram; always confirm right angle with carpenter's square.
   • Shelf boards protruding beyond side board edges prevent proper back panel attachment.
8. 8

   Screwing One Side Board

   ≈ 15 min

   Drive 38mm coarse-thread screws through pilot holes from outside side boards into shelf board edges: two screws per shelf position, 12 screws total for six shelves. Screw heads should be flush or sunk about 0.5mm below the side board surface. Use medium torque on impact driver; final tightening by hand for a quarter turn.

   Drive screws

   コーススレッド 51mm

   ScrewSTEP 8 / 20

   Tip

   • Offsetting two screws slightly vertically increases withdrawal strength.
   • If screw heads are visible, optionally fill holes later with wood dowels to conceal.

   Watch out

   • Over-tightening screws may split the 19mm thick SPF lumber edge; stop at medium torque.
   • If screws go in at an angle and protrude through the opposite side, remove and fill with wood filler, then re-screw at correct position.
9. 9

   Preparing to Attach Opposite Side Board

   ≈ 15 min

   Stand up the side board with shelves attached. Position the second side board on opposite side, aligning the ends of shelves with the pencil lines on that side board. Clamp temporarily. Confirm right angles while the structure is fully upright.

   Build the frame

   Check for square

   AssembleSTEP 9 / 20

   Tip

   • This step is best with two workers: one stabilizes the model, the other clamps.
   • The opposite side board was marked previously; do not remark.

   Watch out

   • Attempting this alone risks shelves falling off and hitting the floor; use two people or lean 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 shelf board edges: two screws per shelf per side, 12 screws total. With both side boards attached to six shelf boards, the main bookshelf structure is complete.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 10 / 20

    Tip

    • After attaching both sides, check level of all shelves with a level; if any shelf is tilted, loosen screws, adjust, and retighten.

    Watch out

    • Do not screw both sides simultaneously; fix all shelves on one side fully before proceeding to the other to avoid distortion.
11. 11

    Checking Overall Level and Diagonal Measurements

    ≈ 15 min

    Place assembled structure on floor and check each shelf's level with a level. Measure diagonals from top left to bottom right and top right to bottom left; difference should be within 5mm. If warped, loosen clamps slightly, adjust, and add screws to fix.

    Check level

    Level ✓

    LevelSTEP 11 / 20

    Tip

    • Diagonal difference over 5mm means parallelogram distortion; correct this before attaching back panel.
    • Back panel increases rigidity; correct warping before fitting it.

    Watch out

    • Shelf boards sagging in center worsens under book weight; shelf length up to 600mm is acceptable; over 1000mm requires reinforcement consideration.
12. 12

    Preparing to Attach Back Panel

    ≈ 10 min

    Place 4mm plywood back panel (900×1700mm) against back of assembly. Align corners and ensure diagonal lengths match the structure (this final correction reduces distortion). Temporarily fix back panel with masking tape.

    Build the frame

    Check for square

    AssembleSTEP 12 / 20

    Tip

    • Back panel suppresses structural distortion; uneven attachment reduces rigidity.
    • Plywood can be easily attached with a tacker; if using small nails, pre-drill pilot holes.

    Watch out

    • If back panel is larger than structure, trim protruding areas. If smaller, leave even gaps about 5mm around edges.
13. 13

    Attaching Back Panel with Tacker

    ≈ 20 min

    Fix back panel to side boards and shelf boards using tacker staples (about 15mm length) or small nails every 100-150mm around edges and along shelf board positions. Start from corners and proceed along diagonals to reduce distortion.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 13 / 20

    Tip

    • A tacker costs 1500-2500 yen and is faster than nails; a worthwhile investment for bookshelf building.
    • Mark shelf positions on back panel with pencil to avoid missing fastening points.

    Watch out

    • Staples that protrude inside the bookshelf can damage books; 15mm staples are appropriate for 19mm thickness.
    • If fastening only along four edges and not at shelf positions, back panel may lift when sagging occurs.
14. 14

    Preparing L-Bracket Attachment

    ≈ 15 min

    Plan to attach four 50mm L-brackets: two on left and two on right at upper back of bookshelf. Position one side on top edge of bookshelf and the other side for wall fixing. Use stud sensor to locate wall studs beforehand.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 14 / 20

    Tip

    • 100 yen store stud sensors are low accuracy; home center sensors (1000-2000 yen) are recommended.
    • Studs are usually spaced at 455mm; once one is found, others can be approximated.

    Watch out

    • Fixing only to gypsum board without hitting studs does not prevent tipping.
    • If bracket positions do not line up with studs, adjust bracket placement laterally so screws hit stud centers.
15. 15

    Attaching L-Brackets to Bookshelf

    ≈ 10 min

    Attach four 50mm L-brackets to upper outer side edges of side boards using 38mm coarse-thread screws through bracket holes. Brackets should be flush with or within 5mm of side board surface, projecting perpendicularly for wall fixing.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 15 / 20

    Tip

    • Ensure bracket bend faces wall and screw holes face bookshelf for correct orientation.

    Watch out

    • Incorrect bracket angle causes gaps between bracket and wall, reducing effectiveness; verify horizontality with a level.
16. 16

    Setting Up Bookshelf and Wall Fixing

    ≈ 20 min

    With two persons, carry bookshelf to installation location and stand it against wall firmly. Using screws 45-50mm long through wall side holes of L-brackets, screw into wall studs for secure anchoring. Fix all four points securely to prevent tipping.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 16 / 20

    Tip

    • Use screws longer than 38mm (recommended 45-50mm) for wall side to reach stud.
    • Wall fixing is critical to prevent injury or death from tipping during earthquakes; do not neglect this step.

    Watch out

    • Gypsum board anchors do not provide sufficient strength; always screw into studs.
    • If a gap of 5mm or more exists between bookshelf and wall, insert shims before fixing; an unfilled gap reduces bracket effectiveness.
17. 17

    Cleaning before Finishing

    ≈ 10 min

    Thoroughly vacuum and wipe bookshelf with dry cloth to remove all dust, oils, and fingerprints before finishing. Cleaning quality critically affects final finish. Optionally, mask the plywood back panel as it absorbs finish quickly.

    Inspect

    No wobble ✓

    InspectSTEP 17 / 20

    Tip

    • Perform wiping in sequence: dry wipe, wet wipe, then dry wipe again for best cleanliness.

    Watch out

    • Residual wood dust causes rough finish; inspect under lamp for thoroughness.
18. 18

    Applying First Coat of Oil Stain

    ≈ 40 min

    Apply oil stain (e.g., Watco Oil, Kinura) with brush over entire bookshelf in order: side board exterior, shelf board surfaces, shelf board interiors, then back panel. After 10-15 minutes, wipe off excess with dry cloth. Use about 60-70% of total oil amount on first coat as absorption is high.

    Paint

    Watco oil / varnish

    PaintSTEP 18 / 20

    Tip

    • Oil stain application requires coat, wait 10-15 minutes, then wiping to avoid sticky finish.
    • Brush width 30-50mm is optimal for bookshelf; too wide brushes miss detail areas.

    Watch out

    • Failure to wipe off excess leaves stickiness for over a week.
    • Plywood back panel absorbs quickly and causes uneven color; apply thinly and wipe carefully.
19. 19

    Applying Second Coat of Oil Stain

    ≈ 25 min

    After first coat dries for 24 hours, apply second coat with about one third to half the amount used in first. Also wipe off excess. Two coats deepen color and enhance protection. Allow 24-48 hours for complete drying.

    Paint

    Watco oil / varnish

    PaintSTEP 19 / 20

    Tip

    • Second coat corrects color irregularities from first coat; apply thin uniformly.
    • Add a third coat if a deeper color is desired.

    Watch out

    • Do not forget to wipe off excess on second coat; thick layers cause unevenness.
    • During drying, prevent dust and insects indoors for best finish.
20. 20

    Completion, Start of Use, and Inspection

    ≈ 15 min

    After full drying of oil (48 hours), arrange books and start use. Place heavy books (encyclopedias, etc.) on lower two shelves and lighter books on upper shelves for good balance and stability. After one week of use, re-check screw tightness and L-bracket security; retighten as needed.

    Done!

    Done — nice work!

    DoneSTEP 20 / 20

    Tip

    • Concentrate heavy books on lower two shelves; use paperbacks and regular books on upper shelves to reduce weight.
    • Reapply oil every 3-5 years to restore luster and protection.

    Watch out

    • Placing books immediately after finishing risks oil transfer to books; dry at least 48 hours before loading.
    • Books absorb moisture; use dehumidifiers in rainy season as moisture causes bookshelf warping.

Warnings

• ⚠️Drill pilot holes before driving screws to prevent wood splitting.
• ⚠️When fixing to the wall, always locate the studs (do not fix only to gypsum board).

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