Airplane Shelf

The Airplane Shelf

I saw this lovely airplane styled shelf on www.ana-white.com.  I fell in love with the potential!  Since my son's bedding has airplanes on it, as does most of his wall art, this shelf would fit in perfectly!  

I sent my husband to Lowe's to bring me back some wood and set to work on this.  

*Side Note* While I was working on my shelf, my husband was working on the headboard for our farmhouse style bed.  I showed him the queen size farmhouse bed that Ana published plans for and told my resident woodworking expert that I wanted it.  Being the engineer he is, he immediately set out to redesign the bed and draw it up in ProE.  Well, several months (and many other projects) later, he finally completed the foot board and is now working on the head board to my beautiful (and very sturdy) platform farmhouse style bed.  

The foot board placed at the head of the bed.  The head board is even bigger.  Next, LOTS of sanding.  

For the first step, I used a miter saw to cut my 1x6 boards and my 1x4 supports.  I cut the 1x6 boards at 30" each and the 1x4 supports at 6" each.  

Two 1x6 boards cut at 30" each.

Step 2: After cutting my shelf pieces, I used my husbands drill press to drill and countersink the holes.  I'm a little surprised he let me use it because it is his new "baby" in his shop.  However, after a brief introduction (i.e. Drill Press 101), I was ready to work.  I measured for the placement of my holes, adjusted the platform height on the drill, and used the laser sight to help line up my hole placement.  I have to say, the drill press is awesome.  My holes are so much straighter when I use this versus the hand held drill.  

Using the drill press to drill and countersink holes in my 1x6 boards.

 *Drill Press Tip*  When using a drill press to countersink a hole, do not apply much pressure and watch your hole carefully!  It is best to "tap" the wood with the countersink bit until you achieve the desired depth.  If you apply too much pressure, you will over-countersink your hole. **

Step 3: After measuring again to check for placement of the 1x4 supports, I clamped my pieces together and used the hand held drill to put pilot holes into the ends of my support pieces.  I drilled through the holes I previously drilled with the drill press, using them as guides.  After drilling all of my pilot holes, I applied some wood glue to the ends of the 1x4 supports and screwed everything in place using 2" screws.   Note: The 1x4s are placed 3" from each edge and flush with the back of the wings.

Drilling the pilot holes for my screws.

*Wood Glue Tip* A little wood glue goes a long way.  When pressure is applied to the wood by clamps and by the force of securing the wood together with screws, some of the glue will squeeze out.  The less glue you use, the less glue will be squeezed out.  Once your project is secure, quickly wipe away any trace of excess glue.  If you don't, stain will not adhere properly where the glue has dried. **

The airplane shelf after completing step 3.  This makes up the structure of the shelf. 

Step 4: Using the miter saw, I cut two 1x2 pieces at 6" each.  These are used as the propeller support and landing gear support.  Then I drew a 4" circle and two 2" circles on the scrap 1x6.  These were cut out using a band saw and then smoothed using a belt sander.  A paint stick from Lowe's received the honor of becoming the propeller.  It was cut at 7" and shaped with the belt sander.

Step 5: After measuring to find the center of my 4" circle, I drilled a hole using the drill press, being careful not to countersink the hole.  On the propeller, I drilled and countersunk a hole in the center.  I then used the drill press to drill some holes for the 1x2 propeller support on both wings.  The center of the 1x2 was placed at 11 1/4".  I drilled the holes for the 1x2 at 3/4" from the edge.  I countersunk both holes.
I then pushed the 1x2 in place and used the holes in the 1x6 wings to drill my pilot holes in my 1x2 ends using clamps to hold everything in place.  Afterwards, I attached the support using 2" screws.

Step 6: I attached my 4" circle to the 1x2 propeller support using some wood glue and a clamp.  I drilled a pilot hole into the 1x2 and attached circle and propeller to the support using a 1 1/4" screw.  I positioned the propeller as I liked and used a hand held screwdriver to tighten it all down.  I choose the hand held screwdriver due to the fragile nature of the paint stick.

The shelf after completing step 6.  It begins to resemble a biplane!

Step 7: I cut two pieces of 1x2 boards at 2 1/2" each.  Then using a band saw, I rounded one end of each and smoothed it with a belt sander.  I then drilled my holes and attached each 1x2 wheel support to the ends of the 1x4 landing gear support.  After attaching the wheel supports, I then attached the wheels to complete my landing gear.

Step 8: I sanded everything in preparation for staining.

I had visited Lowe's previously in the day to purchase wood glue.  While there, I noticed a gorgeous rose tinted stain by Cabot.  I couldn't resist, so I purchased a quart.  (I know!  What am I going to do with a quart of this stuff!?!)

Step 9:  I used my rose tinted stain to apply a light wash of color to the wood shelf.  The landing gear was stained separately and I used my dark Minwax Provincial on it.  I used some white acrylic paint and painstakingly painted the propeller white.

My airplane shelf before applying my 2 coats of polyurethane.  

Step 10:  I used a hand-rub poly in satin finish.  I use old cloth diapers (only used as burp clothes) as cloths to rub finish or poly on wood.  They work great as shop rags for cleanup as well!  As I rubbed on the first coat of poly, I noticed that some of the rose color was coming off. I was okay with this because it allowed even more of the wood grain to show through and it is gorgeous!  

I took the color on my cloth that was mixed with poly and lightly wiped over the white paint on the propeller.  It gave a light wash of rose color to the propeller, instantly making it look aged.  

The finished shelf.