Open Storage Shelf

Dimensions

Cut list

Tools you'll need

• ✓

  Measuring Tape (5m or longer)

  Used to measure each part.

• ✓

  Pencil and Carpenter's Square

  Used for marking lines and confirming right angles.

• ✓

  Saw

  Home center cutting service recommended.

• ✓

  Electric Driver

  Impact driver improves work efficiency.

• ✓

  Sandpaper

  Prepare two types: #120 and #240.

• ✓

  Level

  Essential for checking horizontal alignment 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 1x10 (19×300×1800mm), six shelf boards (19×300×1200mm), one 4mm veneer back panel (1200×1800mm), 48 coarse-thread screws 38mm, and four L-shaped brackets 50mm. Tools include electric driver, saw, measuring tape, carpenter's square, #120 and #240 sandpaper, level, two F-type clamps, brush and paint tray, and a stapler or small nails.

   Measure

   W 1200 mm

   MeasureSTEP 1 / 20

   Tip

   • SPF lumber tends to warp. Check each board visually at purchase and select ones with warping within 1mm.
   • L-shaped brackets and screws are the 'lifeline' for preventing tipping. Never omit them.

   Watch out

   • Check each SPF board for warp, cracks, and knots before purchase. Assembling boards with warping over 1mm will cause distorted shelves.
   • The 4mm veneer back panel is thin and easily damaged during movement. After cutting, store standing up immediately.
2. 2

   Securing the Workspace

   ≈ 10 min

   Secure a workspace tall enough to stand the 1800mm bookshelf upright. Ceiling height should be 2200mm or higher; a floor area of about 1500×1200mm is sufficient. Lay down a blue sheet and support long lumber on two sawhorses.

   Inspect

   No wobble ✓

   InspectSTEP 2 / 20

   Tip

   • Assembly is done lying the bookshelf down and raising it up only at the final step. This makes working possible even in small rooms.

   Watch out

   • Standing up the assembled bookshelf is difficult alone. Two people are recommended for safety.
   • If ceiling height is under 2000mm, the bookshelf may hit the ceiling when standing. Check beforehand.
3. 3

   Creating Cut List and Cutting Request

   ≈ 20 min

   Submit a cut list to the home center for two side boards (1800mm), six shelf boards (1200mm), and one back panel (1200×1800mm). If cutting yourself, support long lumber on two sawhorses and make cross 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. Having all cuts done costs around 1000 yen and reduces time from 30 minutes to immediate completion.
   • Since all six shelf boards have the same dimensions, bundling them for a single cut yields highest accuracy.

   Watch out

   • 19mm thick SPF boards easily warp even with straight cuts. Use a guide to cut straight.
   • 4mm plywood is soft and tends to warp if not supported underneath when cutting.
4. 4

   Sanding All Parts (#120 → #240)

   ≈ 40 min

   Sand all parts starting with #120 sandpaper, then finish with #240. Pay special attention to the shelf support surfaces on side boards, top and bottom of shelf boards, and cut edges. Rounding shelf edges slightly makes handling easier. After sanding, vacuum all wood dust thoroughly.

   Sand

   #120

   SandSTEP 4 / 20

   Tip

   • A smooth shelf board surface helps smooth book insertion/removal.
   • The cut edges tend to raise fibers, so sand carefully starting from #120.

   Watch out

   • SPF lumber is soft. Over-sanding changes dimensions. Use #120 mostly and #240 only for finishing.
   • Rounding corners excessively looks clumsy. Limit to about 2mm radius.
5. 5

   Marking Shelf Positions on Side Boards

   ≈ 15 min

   Place two side boards side by side and mark shelf positions for six shelves with a pencil. Shelf spacing can be six evenly spaced 300mm intervals starting from bottom (1800mm total), or wider spacing on top for display as designed. Stack side boards tightly and mark simultaneously to ensure exact matching positions on both sides.

   Mark a line

   Use a try square

   MarkSTEP 5 / 20

   Tip

   • Clamp the two side boards together before marking so shelf positions match exactly on left and right sides.
   • Setting shelf spacing based on A4 (297mm), A5 (210mm), or bunko (150mm) book heights facilitates storage.

   Watch out

   • If shelf marks on left and right side boards don’t align, shelves will be inserted crookedly; simultaneous marking with clamped boards is essential.
   • Forgetting to account for 19mm shelf board thickness reduces actual spacing.
6. 6

   Preparing Pilot Holes

   ≈ 20 min

   Drill φ3mm pilot holes at the marked positions. Drill from the outer side of the side board through to the shelf board edge. Use masking tape on the drill bit to mark depth. Total depth is 29mm: 19mm through side board plus 10mm into shelf board.

   Drill a hole

   φ3mm

   DrillSTEP 6 / 20

   Tip

   • φ3mm pilot holes correspond to about 70% of the coarse-thread screw 38mm shaft diameter (4.2mm), ensuring no wood splitting.
   • Each shelf board requires 2 pilot holes on each side board (2 sides × 6 shelves × 2 screws = 24 holes). Double-check no holes are missed.

   Watch out

   • If pilot holes are insufficiently deep, screws won’t seat fully; drill slightly deeper for safety.
   • Avoid drilling through the shelf board on the opposite side. Use masking tape as a depth limiter.
7. 7

   Temporarily Fixing Shelf Boards to One Side Board

   ≈ 20 min

   Lay one side board flat on the floor and place six shelf boards upright at the marked positions. Temporarily clamp the boards with F-type clamps and confirm right angles between side board and shelf boards using a carpenter's square. For areas where the square cannot be fitted, check visually.

   Build the frame

   Check for square

   AssembleSTEP 7 / 20

   Tip

   • Insert shelf boards starting from the bottom for stability.
   • Each shelf board ideally needs one clamp. Having six clamps makes the job easier, but two clamps can be used sequentially.

   Watch out

   • Fixing with incorrect right angles will cause the frame to become a parallelogram. Always check with a square.
   • If shelf boards extend beyond side board edges, the back panel will not fit later.
8. 8

   Screwing One Side Board

   ≈ 15 min

   Drive coarse-thread screws 38mm through pilot holes from outer side board into shelf board edges. Use two screws per shelf per side (12 screws total). Screw heads should be flush with or recessed by 0.5mm from side board surface. Set electric driver's torque to medium and finish tightening manually for a quarter turn.

   Drive screws

   コーススレッド 51mm

   ScrewSTEP 8 / 20

   Tip

   • Slightly offsetting the two screws vertically improves pull-out strength.
   • If screw heads are visible, they can be covered later with wood plugs (optional).

   Watch out

   • Over-tightening screws in 19mm SPF lumber causes end grain splitting. Use medium torque.
   • If screws enter at an angle and protrude, remove the screws, fill holes with wood putty, and retry at another position.
9. 9

   Preparing to Attach Opposite Side Board

   ≈ 15 min

   Stand the partially assembled unit upright and align the other side board on the opposite side. Match the shelf board edges to marked lines on the side board and temporarily clamp. Confirm right angles with the unit standing upright.

   Build the frame

   Check for square

   AssembleSTEP 9 / 20

   Tip

   • Two people are recommended: one to hold, one to clamp for accuracy.
   • Markings on the opposite side board were made initially; do not remark.

   Watch out

   • Forcing the operation solo may cause shelf boards to fall to the floor. Use two people or lean against a wall.
10. 10

    Screwing the Opposite Side Board

    ≈ 15 min

    Screw coarse-thread screws 38mm through pilot holes from the outer side of the opposite side board into the shelf board edges. Two screws per shelf per side (12 screws total). This completes fastening both side boards and six shelf boards, forming the main bookshelf structure.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 10 / 20

    Tip

    • After fastening both sides, use a level to confirm shelves are horizontal. If any shelf is tilted, loosen screws and adjust.

    Watch out

    • Driving screws on both sides simultaneously may cause distortion. Fasten one side completely first, then the other side.
11. 11

    Checking Overall Level and Diagonal Measurements

    ≈ 15 min

    Place assembled frame on the floor and use a level to check each shelf’s horizontal alignment. From the front, measure diagonals (top left to bottom right, top right to bottom left) with measuring tape; difference should be within 5mm. If warped, loosen clamps, adjust, and add screws to fix.

    Check level

    Level ✓

    LevelSTEP 11 / 20

    Tip

    • A diagonal difference over 5mm indicates a parallelogram distortion. Correct it before attaching the back panel.
    • The back panel design increases rigidity; correct distortion before its attachment.

    Watch out

    • Shelf boards sagging in center worsen with heavy books. Shelf length of 600mm is acceptable; lengths over 1000mm may require reinforcement.
12. 12

    Preparing to Attach Back Panel

    ≈ 10 min

    Place 4mm veneer back panel (1200×1800mm) against bookshelf back. Align all corners and confirm back panel diagonals match the frame. Positioning the back panel can finalize correction of distortions. Once fixed, lightly tape the panel to the frame with protective tape.

    Build the frame

    Check for square

    AssembleSTEP 12 / 20

    Tip

    • The back panel is critical for rigidity. Installing it slightly skewed reduces stability.
    • 4mm veneer can be easily fixed with a stapler or small nails; pilot holes are required for nails.

    Watch out

    • If the back panel is larger than frame, trim excess parts. If smaller, leave balanced gaps up to 5mm at edges.
13. 13

    Stapling the Back Panel

    ≈ 20 min

    Fasten the back panel to side boards and shelf boards using a stapler (approx. 15mm staples) or small nails. Space fasteners every 100–150mm around perimeter and at shelf positions. Start from corners and continue along diagonals to prevent distortion.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 13 / 20

    Tip

    • Home center staplers cost 1500–2500 yen and speed up work compared to nails; worth investing for bookshelf construction.
    • Mark shelf positions with pencil on back panel before fastening to avoid missing spots.

    Watch out

    • Staples protruding inside the unit can damage books. 15mm staples are appropriate for 19mm thickness.
    • Stapling only along the edges and shelf board lines is necessary; otherwise, the back panel may bulge when bowed.
14. 14

    Preparing to Install L-shaped Brackets

    ≈ 15 min

    Attach four 50mm L-brackets at upper rear left and right sides (two per side). One side attaches to bookshelf top edge; the other side is fixed to wall studs. Locate wall studs with a stud finder beforehand.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 14 / 20

    Tip

    • Low-cost stud finders from 100-yen stores have low accuracy. Higher quality home center models (1000–2000 yen) are recommended.
    • Wall studs are usually spaced at 455mm. Finding one helps estimate adjacent stud positions.

    Watch out

    • If wall surface is only gypsum board and screws don’t hold, anti-tip measures fail. Always fix brackets into studs.
    • If bracket positions don’t align with studs, shift brackets left or right so screws go into the stud center.
15. 15

    Attaching L-shaped Brackets to Bookshelf Side Boards

    ≈ 10 min

    Fix four L-brackets to bookshelf upper side boards externally using coarse-thread screws 38mm through provided screw holes. Brackets should sit flush or with less than 5mm gap from side boards, protruding perpendicularly outward to the wall.

    Drive screws

    コーススレッド 51mm

    ScrewSTEP 15 / 20

    Tip

    • Ensure bracket bends face wall side, and screw holes face bookshelf side.
    • Double check bracket is level to avoid gaps between bracket and wall when fastening.

    Watch out

    • Installing brackets at incorrect angles causes gaps between bracket and wall, reducing effectiveness. Confirm with a level.
16. 16

    Placing Bookshelf and Fixing to Wall

    ≈ 20 min

    Move bookshelf to place (two people recommended), set it flush against wall. From bracket wall-side screw holes, drive coarse-thread screws 45–50mm (included screws or separately purchased) into wall studs. Secure all four brackets to complete anti-tip setup.

    Fix to the wall

    Anchor to studs

    Wall mountSTEP 16 / 20

    Tip

    • Wall screws at 38mm are too short; use 45–50mm screws to reach studs.
    • Fixing to the wall is the most critical step for safety against earthquakes, possible injuries, or fatalities. Do not neglect.

    Watch out

    • Gypsum board anchors alone lack strength. Always screw into studs.
    • If gap between wall and bookshelf exceeds 5mm, insert shims before fastening. Leaving gap nullifies bracket effectiveness.
17. 17

    Cleaning Before Painting

    ≈ 10 min

    Clean entire bookshelf thoroughly with vacuum and dry cloth to remove wood dust, oils, and fingerprints. Cleaning quality greatly affects finish. Veneer back panel absorbs paint quickly; masking it beforehand is optional.

    Inspect

    No wobble ✓

    InspectSTEP 17 / 20

    Tip

    • For best cleaning before painting, follow dry wipe → damp wipe → dry wipe sequence.

    Watch out

    • Remaining wood dust causes rough painting surfaces. Inspect with proper lighting.
18. 18

    First Application of Oil Stain

    ≈ 40 min

    Apply oil stain (e.g., Watco Oil, Kinura) with brush over all surfaces: side board exterior → shelf board top surfaces → shelf board undersides → back panel order. After 10–15 minutes, wipe excess with dry cloth. First coat consumes about 60–70% of total amount due to absorption.

    Paint

    Watco oil / varnish

    PaintSTEP 18 / 20

    Tip

    • Oil stain application requires: apply → wait 10–15 minutes → wipe off excess. Do not skip wiping to avoid stickiness.
    • 30–50mm width brushes are optimal for bookshelf work. Larger brushes cannot reach detailed areas.

    Watch out

    • Omitting wiping leaves stickiness for over a week. Always wipe.
    • Veneer back panel absorbs quickly and can cause uneven color; apply thinly and wipe carefully.
19. 19

    Second Application of Oil Stain

    ≈ 25 min

    After 24-hour drying of the first coat, apply a second coat of oil stain using 1/3 to 1/2 of the first coat’s amount. Wiping excess is again essential. Two coats deepen color and enhance protection. Allow 24–48 hours for complete drying.

    Paint

    Watco oil / varnish

    PaintSTEP 19 / 20

    Tip

    • The second coat corrects unevenness from the first. Apply evenly and thinly.
    • Add a third coat if a darker color is desired.

    Watch out

    • Do not forget to wipe excess on the second coat either; thick layers cause unevenness.
    • Keep the drying area indoors free of dust and insects.
20. 20

    Completion, Use, and Inspection

    ≈ 15 min

    After full drying of oil (48 hours), place books and begin usage. Distribute heavier books on lower shelves and lighter ones on top for balance and stability. One week after usage, recheck the screws and L-bracket fixtures; tighten if necessary.

    Done!

    Done — nice work!

    DoneSTEP 20 / 20

    Tip

    • Concentrate heavy books (like encyclopedias) on bottom two shelves. Use paperback and regular books in upper shelves to reduce weight.
    • Reapply oil every 3–5 years to restore gloss and protective effect.

    Watch out

    • Placing books immediately after finishing results in oil transferring onto books. Wait at least 48 hours.
    • Books absorb moisture, so use dehumidifiers during rainy season. Shelf may warp due to humidity.

Warnings

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

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