DVD and Video Game Tower
Plans and Procedures
1. Complete Bill of Materials for Cost and Lumber Calculations
Tower Sides (2 Sides)
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Rough hand cross cut two boards to 26” in length.
Rough rip both boards on the table saw to 5 ½” in width.
Face joint board on the jointer with the cup side facing down until the board is flat.
Joint the better edge with the flat face against the fence until you obtain an even cut.
Plane both boards down to ¾” thick. Remember on the first pass, place the flat/jointed face
down.
Final rip board to 4 15/16” wide on the table saw.
Final joint the edge just ripped on the table saw 1/16” so that the final width is 4 7/8” wide.
Final cross cut both boards to 24 5/16” long using the compound miter saw.
Using the Radial Arm Saw and the Indexing jig, cut 3/8” x5/8” Dado grooves in both boards.
Sand Outside faces with the Random Orbit Sander using the correct sanding procedure ( 80 grit,
120 grit and 220 grit sand paper.
Tower Tops (2 parts)
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Rough hand cross cut board to 24” long
Rough rip board to 5 ¾” wide on the table saw
Face joint board on the jointer with the cup side facing down until the board is flat.
Joint the better edge with the flat face against the fence until you obtain an even cut.
Plane both boards down to ¾” thick. Remember on the first pass, place the flat/jointed face
down.
Final Rip board 5 5/16” on the table saw
Final joint the edge just ripped on the table saw 1/16” so that the final width is 5 ¼” wide.
Shave 1/16” off one end of the board and measure 10 ¼” long
Final cross cut both boards to 10 ¼” long
Round over both ends of each board and one edge of the board using the ¼” round over bit
and the table router.
Sand Outside faces with the Random Orbit Sander using the correct sanding procedure ( 80
grit, 120 grit and 220 grit sand paper.
DVD/Game Tower Spacer (2 parts)
1.
Find any rippings of the same species of wood that can be edge glued.
2. Joint the edges if safe.
3. Glue edges together using the K-Body clamps and wood glue
4. Make sure to wipe off any excess glue from the top and bottom of the glued up boards.
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If you cannot find any wood to edge glue, follow the following instructions
Rough Rip left over boards from Tower Tops to 5 1/8”
Cross cut left over board to 18” long using the compound miter saw
Face joint board with cup side down if needed.
Joint the good edge (required)
Plane the board to ½”-9/16” depending on the smallest of the top/bottom slot of tower.
Final rip board on the table saw to 4 13/16” wide
Joint the ripped edge 1/16”, making the width 4 ¾” wide
Sand both faces using the random orbit sander and the same sanding process used for the
above parts.
Assembly of DVD/Game Tower
1. Make sure both sides of the tower are the same length. Correct if needed.
2. Make sure both spacers sit flush on the top and bottom of the tower.
3. Using the K-Body clamps, clamp the tower together and rack diagonally to acquire a square
tower.
4. Measure/Preedril Steps. ( 4X)
a. Measure ¼” from the end of the tower and mark lightly with a pencil along the face.
b. Measure 1” from each edge and draw marks creating a center line.
c. Place and 18 gauge brade with the head cut off in a hand drill, not electric drill
d. Use a scratch awl and mark the locations of the holes and drill using caution not to allow
the chuck of the drill to hit the wood and make a mark.
5. Apply a thin bead of glue and spread it out with a brush.
6. Nail all nails in the tower and set them under the wood using a nail set.
7. Wipe off any excess glue that may have leaked out with a wet paper towel.
8. Find the center (lengthwise) of the tower top and spacers.
9. Clad tower to table and mark out 4 screw locations on the top and bottom of the tower spacer.
a. 1 ¼” from edge
b. 1” from end
10. Mark all hole center locations with a scratch awl.
11. Using a hand drill with a 1/” dia./countersink drill bit, drill through the spacer being carful not to
drill through the bottom of the bottom plate or top plate. Do this 8 times
12. Insert 8 #6 x ¾” wood screws keeping all heads aligned with each other.
13. Stain, apply clear coat and wax with Minwax.
Decorative Mahogany Luan Back (after assembly)
1. Measure the back opening of your Tower (height and width)
2. Rip the luan on the table to the width of your toper
3. Cross cut the luan to the length of your tower
4. If the project has not been racked properly and the tower is not square, you may need to use a
block plane to shave down the top and bottom of the luan to fit.