How to Make the Perfect Expandable Bookshelf Using Proxxon Tools

While browsing Amazon, I came across this expandable bookshelf, and immediately thought, "I can make that with my Proxxon tools!!" Using their pictures as a guide, I developed my own plans for a bookshelf that expands from 16" to 29" to provide a minimum of 13" and a maximum of 25¾" book space. 

I made this project from pine lumber because I wanted a rustic, farmhouse finish. The bookshelf could be made of hardwoods for a more polished look.

Here are the supplies you'll need for this expandable bookshelf:

• Eight slats measuring 15" x 1 3/8" x 5/8" (I used 1" x 2" x 8' furring strips)
• Four 8" x 8" blanks (I used a 1" x 10" x 6' pine board)
• Thirty-two 8 x 2½" wood screws
• FolkArt Milk Paint

I used these Proxxon tools to make the bookshelf:

• Proxxon Table Saw FET
• Proxxon Disc Sander TSG 250/E
• Bench Drill Press TBM 115
• Proxxon Professional Rotary Tool IBS/E

This is how I made the bookshelf:

1. Cut the furring strips and pine boards to size using the table saw.
   
   
   
2. Sand the cut ends on the disc sander. Since I was going for a rustic look, I didn't surface sand the pieces.
   
   
   
3. Drill the screw holes in the slats with the bench drill press. The holes need to be 3/8" from the cut end, and 3/8" from each side edge. Setting the adjustable fence to the correct depth for the holes, and using painter's tape to mark a guide for each side of the slat made quick work of the drilling process. You'll see in the photo that I used a piece of waste wood under the slat to minimize tear out.
   
   
   
4.  Next, install a countersink bit in the drill press, and countersink the holes on one side of the slat. Set the depth gauge on the drill press to ensure consistency.
   
   
   
5. Finish the pieces with a color wash. I chose a red/brown wash. You'll want to test the look on a scrap. Thin the paint with water—4 parts paint to 1 part water. If you want a more solid color, then use less or no water. 
   
   
   
6. Work in sections to apply the wash with a brush and immediately wipe with a rag. Let dry thoroughly. If you want more pronounced color, add more coats of the wash, following the apply/wipe procedure. 
   
   
   
7. Now we assemble the pieces. Secure one of the 8" x 8" pine boards in a worktable vise. Use a square to position one of the slats—countersunk holes up—at the end of the pine board.
   
   
   
8. Use the professional rotary tool to drill through the existing holes of the slat into the end of the pine board. Screw the slat in place.
   
   
   
9. Repeat Step 8 on the other side of the pine board.
10. Position the center slat and drill the holes into the pine board. Screw the slat in place.
11. Secure another 8" x 8" board in the table vise, and secure the slats from Steps 8, 9, and 10. Use a square to be sure the slats are accurately positioned. You'll end up with one of the sliding pieces of the bookshelf—pine board sides with three slats on the bottom.
12. Repeat Steps 7 and 8 this time positioning two slats on the pine board. These two slats slide between the three slats already secured.
13. Repeat Step 11, securing the two slats.
14. Mesh these two completed pieces together, and close the bookshelf to its most compact position. Lay the bookshelf on its front side. Attach the three remaining slats for the back the bookshelf as shown in the following picture. Green = slats. Red and blue = pine board sides.
    
    
    

Carole