Computer Workstation

Use arrows to view the project from different angles & magnifying glass to enlarge image.

The Project

The computer workstation has become the "desk" of the millennium. But even the simplest version
can cost hundreds or more at your local computer furniture store. By building our version you'll not
only pocket big savings, you'll also have a strong, sturdy workstation for years to come. And, by
building your own, your total cash outlay for materials for this first-class workstation will be a
fraction of what you would pay for a comparable, commercially built table.

The bonus of this project is that you will learn some new woodworking techniques, such as
component or modular building; that is, building sections which are later assembled to complete the
piece. Additionally, this computer workstation project will help you improve certain skills you
already have, such as edge-joining, design and layout. You'll also learn how to apply a beautiful
finish, which will protect your project from surface damage and keep it looking its best for years to
come.

Computer Workstation
Tools & Materials

Tools Required

Hand Tools

• Pencils
• Ruler (zigzag or ta pe)
• Square (combination or try)
• Assorted files
• Assorted dia. drill bits
• Phillips screwdriver (medium)
• Mallet
• Sandpaper, 80-grit through 220-grit
• Handsaws
 • Hammer and 1/32nd nailset
• Block plane
• Hand screw clamps

Power Tools

• Plate joiner with no. 20 biscuits

• Mortiser
• Saws (band, radial arm)
• Jointer
• Sanders (stationary belt and portable belt, random orbit, pad)
• Planer
• Rasp plane
• Router, assorted cutters
• Table saw with dado head set
• Drill Press (or portable electric drill)

Miscellaneous

• C -clamps
• Bar clamp
• Safety glasses

Materials

Computer Workstation Buying and Cutting List

Key Parts Pcs. Size Material Cut From (buy) *see Notes
3/4 x 26-3/4 x 47-7/8"
A Top 1 Pine 4/8, 1 x 4
(OA)
B Edging, ends top 2 3/4 x 1 x 27-3/4" Pine All edging from 1/5, 1 x 6
C Edging, front top 1 3/4 x 1 x 49-7/8" Pine "
D Legs 4 2 x 2 x 28-1/2" Pine 1/5, 8/4 x 6
Top rails, front and
E 2 3/4 x 1-1/2 x 47-1/8" Pine All rails from 1/7, 1 x 4
rear
F Top rails, ends 2 3/4 x 1-1/2 x 24-3/4" Pine "
1-3/4 x 1-5/8 x 47- All stretchers cut from 1/7, 8/4 x
G Rear stretcher 1 Pine
1/8" 8" board
1-3/4 x 1-5/8 x 24-
H End stretchers 2 Pine "
3/4"
I Dividers 3 3/4 x 4-1/4 x 26-1/2" Pine 1/8, 1 x 6
J Cleat 1 3/4 x 1-1/2 x 22-3/4" Pine Scrap box
K Drawer shelf 1 3/4 x 12-1/4 x 26-1/4" Pine 1/5, 1 x 8

Drawer
L Drawer sides 2 1/2 x 2-5/8 x 12-1/2" Pine 1/5, 1 x 4
M Drawer back 1 1/2 x 1-7/8 x 10-5/8" Pine 1/1, 1 x 4
N Drawer front 1 3/4 x 4-3/16 x 12-1/4" Pine 1/18, 1 x 6
1/4 x 10-1/16 x 11-
O Drawer bottom 1 Plywood 1 sq. ft.
15/16"
Keyboard Platform
P Keyboard platform 1 3/4 x 14-5/8 x 30-7/8" Pine 1/5, 1 x 4
Q** Hand rest 1 3/4 x 2 x 30-7/8" Pine 1/1, 1 x 4
R Stop blocks 2 3/4 x 3/4 x 3-1/2" Pine 1/18, 1 x 6

*Notes:

• The buying column lists the lumber in lumberyard language. Your instructor has probably
already covered the subject of buying lumber; that is, that lumber is purchased using
nominal dimensions, which are not the same as actual dimensions. For example, the listing
(nominally) 1/5, 1 x 6 means you want one 5-ft. length of 1 x 6. The actual dimension for
this board is 3/4 x 5-1/2" by 60 inches long.

• 8/4 in lumber jargon means eight quarters, or 2 inches. Bear in mind that this is the
nominal dimension and that it can and will vary a bit from one sawmill to the next. Take
your ruler along to make certain that the 8/4 stock you buy will allow you to plane the
material to the desired 1-3/4 x 1-7/8" dimensions.

• ** The hand rest installed on the keyboard platform is shaped from a 3/4-in.-thick piece of
pine. For ease of shaping this member, try to select pine without knots. See drawings for
hand rest shape (profile).

Bring the above materials list to the lumberyard with you when you go to buy the materials.

Hutch Materials Lists

Note: The left-hand hutch top is referred to as L; the right-hand cabinet as R.

L HUTCH

Key Parts Pcs. Size Material Cut From (buy)

L1 Sides 2 3/4 x 13 x 29-1/2" Pine 2/6, 1 x 6 & 1/6, 1/4
L2 Shelf 1 3/4 x 13 x 21-3/4" (left unit) Pine 1/4, 1 x 6 & 1/2, 1/4
L3 Back 1 3/4 x 7-1/2 x 21-3/4" (right unit) Pine 1/2, 1 x 8
L4 Dividers 2 1/2 x 7-1/8 x 9" Pine 1/2, 1 x 8

Miscellaneous

Table: 24 number 20 biscuits; 1/3 length 1/4" dowel, carpenter's glue, assorted finishing nails (3d
and 6d); assorted grits sandpaper; one Knape and Vogt Model 1300, 16" drawer slides; one 3/4"
dia. white ceramic knob with rh screw (or, pull of choice); brads; glue; two 1 x 1 corner braces;
four 3-prong tack glides, 7/8" dia.

Hutch: 4 1/4-20 Teenuts ® with 1-1/2" 1/4-20 fh screws; 3 3/4 x 3" mending plates with 12 1-1/4"
x no. 7 fh screws; eight metal shelf clips (for adj. shelves in right hutch)
CD Box: Glue, brads, no.0 biscuits

R HUTCH

Key Parts Pcs. Size Material Cut From (buy)

R1 Sides 2 3/4 x 13 x 29-1/2" Pine 2/6, 1 x 6 & 1/6, 1/4
R2 Shelf 1 3/4 x 13 x 24-1/2" Pine 1/4, 1 x 6 & 1/2, 1/4
R3 Back 1 3/4 x 7-1/8 x 24-1/2" Pine 1/3, 1 x 8
2/8, 1/6 & 1/8, 1 x 4 (for R4, 5, 6
R4 Center divider 1 3/4 x 13 x 22-1/8" Pine
& 7)
R5* Fixed shelf 1 3/4 x 13 x 13" Pine "
R6 Bottom shelf 1 3/4 x 13 x 10-3/4" Pine "
Adjustable
R7 2 3/4 x 13 x 10" Pine "
shelves
1/2 x 7-1/4 x 8-3/4"
R8** Dividers 2 Pine 1/2, 1 x 8
(overall)

• *Fixed shelf R5 is optional; install it only if you want or need it. If you do opt to install it,
first check the actual dimensions of your right hutch; this way you can cut the member to
custom fit.

• **Plane 3/4-in. stock to exact 1/2-in.-thickness and cut tenons on bottom and back edges
as shown in drawing

CD Box Optional
Key Parts Pcs. Size Material Cut From (buy)
CD1 Top and Bottom 2 1/2 x 5-1/8 x 12-3/8" Hardwood* 1/4, 1 x 6 (see notes)
CD2 Ends 2 1/2 x 5-1/8 x 10" " "
CD3 Center divider 1 1/2 x 5-1/8 x 9" " "
CD4P Back 1 1/4 x 9-15/16 x 12-5/16" Plywood 1 18 x 18" piece, if available

Notes:

• *Since the box will be subject to heavy usage, we recommend constructing it of hardwood,
such as maple or birch.

• Hardwood comes rough-dressed; make sure you select a piece that measures at least 5-1/2
in. wide, to allow for ripping to desired width. Then, plane the wood to 1/2-in. thickness.

• The CD box shown was sized to suit Kensington's QuickTrieve™ model CD Holder. These
are available at better computer supplies stores. Or, if preferred, you can customize a box
to suit a personal collection of CDs. If you elect to build a customized box, first be sure its
outside dimensions will fit in the appropriate well of the right hutch.

Finishing Products

• Minwax® Gel Stain, Honey Maple

• Minwax® Wipe-On Poly

Alternate Finish Choices (choose one)

• Minwax® Wood Finish™ and Minwax® Fast-Drying Polyurethane

• Minwax® PolyShades® One-Step Stain & Polyurethane

Miscellaneous
 • Professional strength wood glue
• Paint thinner, if necessary
• Tack cloths
• Clean rags
• Water-filled metal container with lid
• Natural-bristle brush (if needed)

Before You Begin

Craftsmanship begins and ends with good work habits. Make it a habit to carefully review the plans
for every project before picking up any tool or purchasing materials. Before starting this project,
take time to discuss your project with your instructor: You'll avoid frustration and wasted materials.

Procedure

Construction begins with the workstation table. Be aware that the dimensions used are standard,
since the aim is to create a piece of furniture that provides optimum comfort for the person working
at it. The monitor and keyboard elevations are of primary importance. You may want to evaluate
the most comfortable heights for working at a computer and, should they vary from the shown
dimensions, make changes on the drawings so you can custom-build the table to suit your own
needs.

You are advised to work with the dimensions given on the drawing, however, since these are in
accord with accepted architectural standards.

START WITH THE TABLE

1. Start by cutting the 1 x 4 stock for the top slightly longer than the top's finished length.

2. Check all edges for warp, cupping and square: Board edges must be perfectly true if you
are to achieve almost-invisible joints in edge-joined work. To be sure that yours will be, run
all board edges through the jointer.

3. Next, lay out the boards on your worktable and arrange them so they produce the most
pleasing grain appearance. At the same time, make sure you flip the boards so that the
annular rings in abutting boards alternate (i.e.: The rings of the third board should be
positioned the same as the rings of board number one, and, so on). Annular rings are
alternated in edge-joining to further minimize chance of warping or cupping.

4. When satisfied with board arrangement for the top, using a pencil, make marks where the
biscuits are to go.

5. Using a plate joiner and the marks you just made, plough the biscuit grooves to suit no. 20
biscuits.

6. Assemble the table top using glue and no. 20 biscuits.

7. Use at least three bar clamps to hold the setup securely while the glue dries. Place one near
each end and the third, centered on the opposite side of the table top.

8. Allow clamped setup to dry for 24 hours.

9. The next day, remove clamps and scrape off any glue squeeze-out using a sharp cabinet
scraper. Finish the smoothing step by belt-sanding the complete top; first with 80-grit
abrasive, then with 100-grit.
 10. Finally lay out the top for exact width and length. Using either a table or circular saw, cut
the ends to produce top's exact length. Then, rip the top to its exact width on the table
saw. Note that the top (at this point) is cut to the dimensions shown in the drawing--
without the edging strips in place on front and side edges. Set top aside.

11. Rip edging strips B and C to size and install them on the top using glue and 1-1/2 in.
finishing nails. Use miter joints at the corners and be sure to use glue in those joints. The
next day, after the glue has dried, secure the miter joints by driving a pair of opposing 1-
1/4 in. brads through each mitered corner. Finally, set all nailheads slightly below the
surface. Set top aside.

Cabinetmaker's Tip: When gluing up a table top, professionals never use boards wider than 1 x 4
nominal. Be aware that wider boards greatly increase the risk of warping and cupping as the wood
dries, generally during the winter months or in a heated home.

12. Cut the remaining structural members for the table to size and length. Notice that the legs
are a full 2-in. square. You may be required to alter the leg dimensions, depending upon
what your lumberyard has in stock. If you cannot get full 8/4 stock, it may be necessary to
trim the stock you have to create legs either 1-3/4 or 1-7/8 in. square.

Cabinetmaker's Tip: Do not cut any of the materials for either the keyboard platform or drawer
until after your basic table is built and assembled. At that time you can take actual dimensions,
sizes, etc. for these members directly from the table. This will ensure both perfect fit and minimal
wasted materials.

13. Carefully lay out for the mortises in the legs. If available, use a bench top mortiser to bore
the mortises in the legs. If your shop lacks this useful tool, create the mortises by boring
overlapping 1/2-in.-dia. holes and cleaning the holes square using sharp chisels.

14. Lay out the stretchers (to legs) and make mating match marks where each stretcher meets
a leg. (Note: Use marks that won't confuse later like I, II, III and so on.) Then mark each
piece for tenon to be cut so it will mate tightly with its mating leg mortise. Carefully cut the
tenons using a back saw; clean up tenons as necessary with a sharp wide chisel. Test-fit all
undercarriage pieces with tenons in their respective leg mortises. Do this testing dry,
without glue, before proceeding with final assembly.

15. Next, set up the table saw with dado head and rip fence so you can plough the grooves,
which will receive the tabletop hold-downs. These will be ploughed in the inside surfaces of
the front and back rails.

16. Because it goes a lot faster with the parts disassembled, sand all parts smooth using a belt
sander and 120-grit paper.

17. Assemble the table as shown in the drawing, using glue. Working quickly, locate the dowel
positions on the legs and bore the necessary holes so that the fully seated dowels will be
inserted through the tenons and into the leg on the far side. Apply glue to dowels before
inserting them into their holes; tap dowels home with a wooden mallet.

18. Check the table setup for square using a framing square. When satisfied with squareness,
secure the carcass by tacking diagonal braces across opposing corners. Then clamp the
setup so the joints will be immobile while glue sets.

19. Use appropriate -length bar clamps: You will need two with 5 -ft. capacity and three with 30-
in. capacity.

20. The next day, the top can be positioned on a worktable, bottom-side up, and the table
undercarriage (also turned upside down) located on it. Check with a ruler to make certain
the top's ends are equally distant from the end stretcher plane, and that the top's rear edge
is flush at back. When the undercarriage is properly positioned, hold it that way with a
 couple of c-clamps while you position and install the hold-downs with wood screws. When
all is secured, remove the c-clamps and flip the table right side up.

Cabinetmaker's Tip: Though it is a basic technique, make sure you protect the wood surfaces
when clamping. If your clamps do not have plastic shields, use scrap wood between clamp jaws and
wood surface to prevent jaw marks from clamp pressure.

21. Cut parts I and K for the drawer compartment to size and install on the table using
carpenter's glue and 1-1/4 in. screws (or air-driven 1-1/2 in. nails). (see illustration)

22. Cut the parts for the drawer and sand all members smooth, working up to 120-grit paper
before assembling the drawer. Take time to study the drawing to be sure you understand
how the drawer front is rabbeted; i.e., the drawer front should conceal the compartment
members (parts I in illustration).

23. Lay out and bore the hole for the drawer knob in the drawer front.

24. Insert drawer into its recess and position it in the closed position. Check the front to make
sure that it fits, and conceals the vertical members behind the front. Make any necessary
adjustments.

25. To prevent the (short) drawer from falling out if pulled forward too vigorously, install the
shaped 1/4-in. plywood stop as shown. Bore a pilot hole through the plywood. Then, hold
the stop in place with a 5/8-in. rh screw. Tighten the screw until the stop can be rotated to
stay in the vertical position. Finally, install the drawer and rotate the stop to the vertical
(drawer stop) position, and tighten the screw a tad more to ensure it remains vertical.

26. Next, go to work on the keyboard platform. Cut the boards for it and edge-join them using
glue and no. 10 biscuits. As you did for the tabletop, alternate the annular rings of abutting
boards to minimize chance of warping. Apply clamp pressure and leave the setup overnight.

27. Next, lay out and install the platform's slide hardware on table and platform sides. Install
the keyboard platform's stop blocks at the ends of the table-mounted slides. Note: Do not
use glue on the stop blocks since you may have to reposition them in the future.

28. Insert platform into the table.

29. Push platform to the closed position to make sure it is flush with table front; adjust stop
blocks if it is not.

30. Cut the piece of lumber for the hand rest and shape it using a block plane and belt sander.
When satisfied with its contour, install it on the platform using glue and countersunk wood
screws from below.

Except for its final sanding and the finishing steps, your table is now complete.

Optional: You may want to install furniture glides on the bottom surface of all legs to prevent (or,
at least minimize) the table from rocking should it eventually be placed on an uneven floor. If you
do decide to add glides, buy the 3-prong type of at least 7/8 -in. dia.

Procedure - Part 2

Building the Hutch Top

The hutch top for the Computer Workstation is easier to build than the desk. However, since the
upper section of this project is in prominent view, build and finish it with the same care, patience
and precise workmanship that you used in building the table.

Build the hutch top in two sections; these are then joined for maximum rigidity after being installed
on the desktop. By doing this, it's possible to alter the design of one or both units to suit your
equipment and taste.

The hutch size, overall, is determined by two factors:

(a) The left unit is sized to accommodate a 21-in. monitor and,

(b) The right hutch will store computer-related paraphernalia such as CDs, floppies, notepads, etc.

As mentioned earlier, hutch sizes can be altered. If your monitor varies from 21 in. or if you want to
customize the unit to adapt it for other uses or storage, you may take some liberties in its design.

Before You Begin

1. Start by cutting the boards for the legs (sides) to length, but cut them slightly longer than
the finished sides will be. (In this case, that means about 30 in.) Note that each side
consists of two lengths of 1 x 6 and one length 1 x 4. This will give you four stacks of three
boards each which, when joined, will be both longer and wider than the required 13 in.

2. Lay out each set of three boards to achieve the best grain match for each leg and, at the
same time, try to alternate annular rings on abutting boards to minimize chance of warping
or cupping. When satisfied with arrangement, lightly draw a cabinetmaker's triangle across
the face of each of each setup: This way each set of three boards can be quickly returned
to your preferred layout of them.

3. Next, joint all edges in the four piles; check the mating edges as you go (an easy step
because you have the cabinetmaker's triangle for reference) to ensure that joints will be
tight and neatly matched when the boards are joined.

4. Align the first set of three boards for the first leg and carefully mark biscuit locations.
Important: make sure you do not position a biscuit in the top portion of each leg area,
which is shaped later; you do not want the shaping to expose a biscuit in the edge. Plough
the mortises to receive the no. 20 biscuits. Then, making certain you keep the three boards
together as a set, put them aside on the work bench while you repeat this procedure for the
following three sides (legs).

5. Start by gluing-up the boards for the 13-in.-wide "legs" or sides. Refer to your
cabinetmaker's triangle to quickly return the boards to the preferred grain layout you
selected earlier. Position each set of boards as you work. For legs glue-up, you will need at
least 12 bar clamps, 3 per setup. Have these, as well as the glue, a glue brush and biscuits
at hand before starting the assembly step.

6. Apply glue to mating board edges and biscuits and assemble the first three boards. Ends
should be aligned and boards should lie flat against bars (i.e., no bow) when clamp
pressure is applied. To minimize the chance of cupping or bowing occurring when clamp
pressure is applied, use a pair of clamps on one side of the boards, positioned about 4 in.
from each end and one clamp at center on the opposite side. Put the clamped setup aside
and allow to dry for 24 hours. Repeat assembly procedure for the remaining three sides.

7. The next day, remove the clamps and trim the four legs so all four are exactly the same
size--13 in. wide by 29 in. long. Crosscut all boards to length on the radial arm saw, using a
stop block to ensure all are the same length. Then, on the table saw, rip boards to width,
 taking some stock off both front and back edges (this will remove any edges dented during
handling, clamping, etc.).

8. Tack two of the legs together for the right hutch (R1) and two for the left (L1) after aligning
each pair so all edges are flush. Hold them that way for the shaping which follows, using a
half-dozen or so 1-1/4 in. brads driven flush.

9. Refer to the drawing of the shaped top, shown on 1 -in. squares in the drawing, to make a
template of 1/4-in. hardboard or plywood. When satisfied with template's layout, cut it out
using saber or scroll saw. Sand the cut edge smooth.

10. Use this template to trace the shaped tops to the two pairs of legs you previously tacked
together. Cut out the shape using saber or scroll saw.

11. Sand the scroll shapes smooth using either a spindle or drum sander chucked in the drill
press.

Note: Since the dividers used on the fixed top shelves repeat the symmetry of the scroll shape used
on the legs, set the scroll template aside for reuse later. When you come to make the dividers, you
can simply refer to the drawing for shape then re-cut the template for use as a divider template.

12. Repeat the board layout and edge-joining steps to make all the shelves for your two units
both finished and adjustable. All of these should be slightly oversize overall when they're
glued-up; they will be trimmed to fit exactly after hutch units are assembled.

Cabinetmaker's Tip: You can edge-join the boards for both hutch tops in a single session as long
as you use identifying marks. Make marks lightly with a soft pencil on the back edges of boards.
(Use R for right cabinet; L for left.)

Cabinetmaker's Tip: Since you have cut your boards so that each side (leg) setup will be slightly
oversize when assembled, there is no need to place scrap blocks between the clamp faces and wood
(to prevent marred edges). Board lengths and widths will be trimmed in the next step, and clamp
marks will be cut off.

Note: The following instructions take you through the steps for building the left hutch, the one that
houses the monitor. The same construction steps are used to build the right hutch except for the
addition of the adjustable shelves. The required steps for installing these are explained below.

13. Before laying out the shelf dadoes on the legs for the left hutch, measure the monitor that
will be used on your workstation. Everything begins with that dimension. Make sure that
the distance from leg bottom edge to bottom plane of dado provides adequate clearance for
your monitor's height. (Your monitor size determines the fixed shelf location in the left
hutch.) You will have to alter the right hutch dimensions so the two fixed shelves remain in
line. Also, if the left hutch width dimensions are altered, the right hutch must be adjusted a
corresponding measurement so that the hutch sits on the table with a 1-in. setback from
table edge, left and right.

14. Since the legs (L1) for the unit have already been sized (step 7), you can now lay out the
dadoes to receive the fixed shelf (L2).

15. The dadoes for the fixed shelf should be perfect mirror images in left and right legs, so
make sure the legs will be exactly opposite each other in the finished cabinet. Here's how to
do it:

16. Position the two legs on your worktable back-edge to back-edge and clamp them so they
cannot move.
 17. Lay out for the dado to be rabbeted in both legs and plough it using a 3/4-in. straight
router cutter set to a depth of 3/8-in.

Cabinetmaker's Tip: On work such as this, where there is no room for error, you must always use
a guide when ploughing with a router. Be certain you clamp on a guide which puts the router cutter
right on the mark. Hold the router shoe firmly against the guide as you cut and, to further minimize
chance of a cutting error, push the router with a slow, easy-to-control feed rate. To be extra safe,
you can clamp a guide so both sides of the router shoe will be guided and to eliminate any
possibility of the router "walking" off the cutting mark. If you opt to cut your dadoes using the table
saw, make certain you use a miter gauge hold-down to prevent lateral movement of the work piece
as the saw blade does its cutting. You must use a stop to position each workpiece accurately before
it is pushed into the spinning blade. This ensures that the dadoes in both legs are positioned the
exact distance from the leg end. If you have never done repetitive crosscutting on the table saw,
discuss this step with your instructor before proceeding.

18. Next, insert a 3/8-in. rabbet cutter in your router and plough the blind rabbets in the back
edges of both legs to receive the back (L3).

19. Assemble the two legs, fixed shelf and back without glue so you can check all for fit; use
small (1-1/4 in.) brads if necessary to temporarily hold the parts together so you can do
your visual check. Now lay out for the 5/16-in.-wide dadoes that will hold the dividers used
in the fixed top shelf. Mark both the shelf and the back at this time.

20. When satisfied with fit, disassemble the hutch and abut the fix ed shelf and back with the
marks for the dadoes lined up. Clamp the boards together so they will not move and,
starting at the back edge, rout the dadoes across, stopping shy of the front edge in order to
create the blind dado as shown in the drawing. Afte r routing, the front round corner can
quickly be made square (to receive the divider) using a sharp 1/4-in.-wide chisel.

21. Reassemble the hutch using glue and fasteners of choice. Note: Because of their superior
holding ability, you can use pneumatically driven 1-1/2 in. nails to join parts here. These
are driven slightly below the surface and the indents can be filled with Wood Filler. Or, if
preferred, 1-1/2 in. fh wood screws which are then covered with dowel plugs. If you opt for
the latter, remember that you must lay out for the screw pilot holes - for body, shank and
counterbore - before you start the assembly step.

22. With left hutch complete, stand it upright on the workstation table, flush at back and with
approximately 1-in. setback from the left table edge. Then, measure the distance from the
outside plane of the right leg to the same width setback at the right table edge. This
measurement is the outside (i.e., overall) width dimension of your right-hand hutch. As
stated earlier, this measurement may differ from our drawing depending upon how the left-
hand hutch is sized. If there is variance with the plan drawing, now is the time to calculate
all dimensional changes and to mark them on your drawing--before starting any work on
your project wood for the right hutch.

23. The right-hand hutch is constructed using the same procedure as for the left--except for
two steps you must take before assembly: a) The holes for the adjustable shelves should
be laid out and bored; you won't be able to fit a drill between legs R1 and R4 after the unit
is assembled. And, b) the dado for the middle leg (R4) must be routed in the underside of
fixed shelf. Attempting this after assembly could result in damage to shelf legs. When the
right unit is complete, set it atop the table abutting the left unit. Recheck both the left and
right setbacks, the tabletop reveal, to make sure the left and right legs are equally distant
from table edge. If the distance varies, even slightly, move units left or right to achieve
that goal.

24. When satisfied with their location, position a pair of handscrew clamps on the legs at center
to hold the two units together. With a pencil, lightly mark the front corner of both the left
 and right (outside) legs and make match marks on tabletop. Next, carefully locate the
points and make marks on both the tabletop and the legs to indicate where you must bore
the holes to receive the dowels, which serve as keepers when the unit is assembled. Note
that this is back about 1 in. from front edge of vertical and cente red on leg width.

25. With handscrew clamps still in place, lay out for the Teenuts ® to be installed on the middle
legs. The fastener's locations aren't critical but, for the sake of craftsmanship, they should
look precisely placed. Then bore the needed holes.

26. From the left side (i.e., the monitor's hutch), start by boring the large dia. holes to suit the
Teenut, to 1/2-in. depth. Then insert a 5/16 -in. bit and bore through at center of each
counterbore to receive the machine screw.

27. Then switch to a countersink and, in the right hutch, countersink all four holes to receive
the machine screw head.

28. Tap the Teenuts in place and secure them with the machine screws.

29. With the hutch unit still aligned on the table, position the mending plates on the three legs;
one on each outside leg and the third on the center leg. Mark the four screw hole locations
for each plate. Bore all screw pilot holes but do not install the mending plates as yet.

30. Carefully tilt the hutch back until it is fully supported and resting on its back. Next, bore the
3/8-in.-dia. holes in outside legs and the table top to receive the keeper dowels. Then, glue
the dowels into the legs so just about 3/4 -in. of dowel protrudes. Glue is used in the one
side only so the hutch can be lifted off whenever necessary (i.e., for a move).

31. Wait one day, to make certain dowels are permanently affixed into the legs, then, bring the
hutch to the upright position and insert the dowels into the mating holes in the table top.
Now you can install the mending plates using the screw holes you bored earlier.

32. Your Computer Workstation is now complete. We also give instructions for an optional box
which can be used to hold CDs close at hand. You may, however, prefer to custom design a
box to suit the "extras" you frequently work with. In this case, the box shown here is a
good starting point for your box.

Note: Leave your workstation assembled until you have completed constructing all the peripheral
parts (CD holder, dividers, etc.), because you want to be able to test fit these pieces before
finishing the table. When satisfied all parts fit as they should, you can disassemble the hutch and
table to simplify the finishing step. Be sure to save all of the hardware and fasteners in a covered
container so you won't have to hunt for them when it is time to reassemble your workstation.

Procedure - Part 3

Dividers for Top Shelves

To ensure the wood in the dividers matching the wood used in the workstation, we planed 3/4-in.
stock from the same pile to 1/2-in. thickness, then created tenons on the bottom and back edges
(see below). You could use 1/4-in. plywood here and save a little work, but because of the exposed
ply edges, the finished look will not be nearly as handsome.

Since the table saw is used to remove a scant amount of material from the divider stock to create
the tenons, read the Cabinetmaker's Tips below to learn the safe way to do this.

Here are the steps for making the dividers:

 1. Cut the 1/2-in. stock to the divider size given in cutting list.

2. Next, to work production-fashion, align the edges of the four pieces. Then, while holding
them fast, drive three 1-in. brads through the pile.

3. Using your previously made pattern, trace the divider's scroll shape onto the top work
piece.

4. Cut all four at one time using the bandsaw.

5. Sand all edges smooth using the stationary belt sander along the straight edges and the
spindle sander for the scroll shape. Lacking a spindle sander, chuck a sanding drum in
either portable drill or drill press.

6. Separate the pile, remove and discard nails and set dividers aside.

7. Set up the table saw so you can safely remove about 1/8-in. from both sides of each
divider, along the bottom and back edges. See Cabinetmaker's Tips, below. Note: The exact
thickness to remove will be determined by the actual thickness of your stock and the width
of the dadoes ploughed in shelf and back. The tenons you create on the dividers must fit
freely in those dadoes.

Cabinetmaker's Tips: Never lay out a shape on your project wood; always make a template or
pattern first. You can use either 1/4 -in. hardboard or plywood--or even sturdy cardboard. Lay the
shape out on your template material following the pattern given in the plan. Cut it out using saber
or scroll saw (or razor knife if template is cardboard). File and sand all cut wooden edges to remove
"whiskers" before using the pattern to transfer the shape to your project wood.

When a small, identical amount of wood must be removed from a number of surfaces, the most
accurate technique is to set up the saw so that the waste is between the blade and fence. That is
the case here, where approximately 1/8-in. is removed from both sides of the bottom and back
edges. This creates tenons to fit in the dadoes provided for them. However, whenever the saw blade
is this close to the fence, there is very real risk of the blade engaging the metal fence: this can be
dangerous at worst, blade damaging at best.

For safety, always install and work with a wooden auxiliary fence whenever you are faced with doing
this type of cutting on the table saw. In order to cut the dadoes on the 7 x 9-in. dividers, make an
auxiliary fence from a length of 1 x 6." Line the board up with the rip fence and with an awl, make
prick marks through the holes on your fence. Use 3/16-in. dia. fh machine screws and wingnuts to
secure the auxiliary fence to rip fence. Caution: Make certain the screw heads are perfectly flush
with the wood's surface when the board is secured tight against the fence by the wingnuts: the
work piece must be able to slide past without interference when you make your cuts.

If you have never installed and worked with an auxiliary fence on a table saw, make sure you
discuss the setup with your teacher before its installation and use.

The CD Box

The box shown in the plan was built to house a commercially available plastic CD box (see Materials
list). Slotted plastic sheets are created for CD storage. Many mail order woodworker's supply houses
offer these. They are available in both end and center CD holder configurations and are installed
using polyurethane glue. If you want to build a custom CD box, make sure the box (i.e., its overall
dimensions) fits in the right-hand hutch.

Making the Box

1. After cutting all parts to sizes shown in drawing, sand them smooth starting with 100 -grit
and finishing with 120-grit abrasive paper.
 2. The corners are mitered and held secure with no.0 biscuits. Or, if preferred, you can use
splines. Here, simply pass the miter faces through the table saw blade to a depth of about
3/4-in. and join the mitered corners using 1-1/2 in.-wide splines. If you opt for the latter
technique, you may want to cut thin strips of molding to glue on the front edge to conceal
the splined corners.

3. The back is of 1/4-in. cabinet grade plywood; install it using glue and 1-in. brads.

Finishing

Read through all instructions on the can labels. This holds true no matter what finish you decide to
apply. There are a number of finishes available that produce professional-looking results. We
recommend using Minwax® Gel Stain for this project.

Working with Gel Stain

1. Minwax® Gel Stain is a smart choice for this project because the sta in provides rich, even
color and will not drip or run on vertical surfaces. Check all surfaces for smoothness and, if
any rough spots are found, sand lightly with 150-grit paper. Dust and wipe with a tack
cloth.

2. Start with the tabletop surface, since Gel Stain is great for evenly staining large areas at a
time. Apply the stain liberally with a clean, lint-free application cloth that is saturated with
stain.

3. Wait 3 minutes and, using a clean rag, wipe in the direction of the grain to remove excess.
If a richer color is desired, apply another coat after 12 hours.

4. Repeat the above steps for the balance of your table, staining just a manageable area at a
time.

5. When the table is stained, move on to the hutch tops and CD box.

6. Set the entire unit aside to dry overnight.

7. When the unit is dry, apply a protective topcoat such as Minwax® Wipe-On Poly or Minwax®
Fast-Drying Polyurethane

Computer Workstation

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Computer Workstation

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Computer Workstation

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Computer Workstation

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Computer Workstation

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 Computer Workstation

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Computer Workstation
Computer Workstation
Tips Summary
 • You can slightly round or "break" sharp edges on raw wood by using 100-grit paper in the
pad sander. For a more pronounced rounding-over, round the edges with the router and a
1/4" rounding-over bit.

• Sand raw wood to at least the 150 -grit level. Use even higher grits for hardwoods such as
walnut and birch.

• All stains and finishes should be allowed to dry thoroughly between coats.

• Sanding between coats should be done with 220-240 grit sandpaper.

• Apply water-based finishes, such as Minwax® Polycrylic®, with quick, with-the-grain strokes.

• To lighten or customize any wood tone to suit a personal preference, thin the stain of choice
with Minwax® Wood Finish™ Natural, per label instructions. In general, you will achieve
your desired tone by mixing two parts of the Wood Finish™ stain color with one part of
Wood Finish™ Natural. To be safe, always test your stain on scrap stock before applying it
to your project wood.

Cleanup

If you have product left over, wipe the can rim to remove all product in the rim. Liquids left in the
rim can dry out and prevent the lid from forming a tight seal.

Clean all brushes used for oil-based finishes with mineral spirits.

Safe Disposal of Rags & Waste

Please be mindful of the safe way to dispose of used wrap and other waste. Remember that rags,
steel wool and other waste soaked with oil finishes, mineral spirits, and turpentine may
spontaneously catch fire if improperly discarded.

Always place these items in a water-filled metal container immediately after use. Tightly seal the
container and then dispose of it in accordance with local fire regulations. Be sure to keep the
container out of reach of children.