Materials
- 3/4" Plywood; 2' x 4': 1 Piece
- 3/4" Hardwood; 5" x 36": 1 Piece
- 1 1/2" Wood Screws: 1/4 lb.
- 1 1/4" Kreg Screws: 1/4 lb.
- Wood Glue
- Sandpaper
- Stain and/or Poly
Tools
- Wood Planer
- Table Saw
- Belt Sander or 120 grit sandpaper and a block (320 grit for finish sanding)
- Tape Measure
- Pencil
- Corner Rounding Template
- Miter Saw
- Band Saw and/or Jig Saw
- Power Drill with DeWalt 9/64 Tapered Bit with Plug Cutter for Pilot Holes
- Router with Round-over Bit
- Kreg Pocket Hole System
- Screw Gun
- Clamps: Bar Clamps and Gripping Clamps
Step 1: Cut the Shelf Pieces - Determine the desired size of your Microwave Shelf or use the dimensions provided here for a 24" cabinet width
- Select 3/4" Plywood: Using a Table Saw, cutout the Bottom, Two Sides, Back and Top panels per the dimensions listed above
- Select the 3/4" Hardwood: Using a Table Saw, rip two, 1/8" strips for Facing Material
- Select the Facing Material: Cut and Glue the Facing/Finishing Strips to the front edges of the Top and Bottom Panels
- Select the Bottom Panel with the glued Facing Strip: Using a Band Saw, cut a notch on each side of the front edge @ 3/4" x 5" to recieve the Hardwood Side Supports
Step 2: Drill the Kregg Holes - Select the pieces from Step 1
- Using a Pocket Hole System and the images above as a guide, drill all the Pocket Holes on the exterior surfaces that will be concealed by the adjacent cabinet sides
- Using a Screw Gun and a 9/64th bit, pre-drill holes along the edges of the Back and Top Panels to receive the 1 1/2" Wood Screws, as shown above
Step 3: Assemble the Shelf - Select the Pieces
- Select the Bottom and Back Panels; Using glue and Kregg Screws, attach the Back to the Bottom Panel, as shown above
- Select the two Sides; Using Glue, Wood Screws, and Kregg Screws, attach the Sides to the Back and Bottom Panels, as shown above
- Select the Top Panel; Using Glue, Wood Screws, and Kregg Screws, attach the Top to the Sides and Back Panels, as shown above
Step 4: Cut and Attach the Side Supports - Select the 3/4" Hardwood and the assembled Pieces from Step 3
- Select the Hardwood; Using a Band Saw, cut the Left/Right Side Supports @ 5" x 15" (make a template to create the curved lines), as shown above
- Select the two Supports; Using a Belt Sander, sand the curved edges smooth; Using glue and Kregg Screws, attach the Supports to the Bottom and Side Panels, as shown above
Step 5: Finish the Microwave Shelf - Select the completed Shelf
- Perform a final sanding of all surfaces
- Apply Stain and Poly to the Shelf (Apply multiple coats)
Copyright 2013 - Wayne Murray
If you are a member of a non-profit organization and have any requests or suggestions regarding projects for your group, you can send Rod an email at: rodneyg@cheqnet.net
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