solutions for sagging shelves Strong & Sturdy …

1 All about < strong >solutionsstrong > for < strong >saggingstrong > < strong >shelvesstrong > < strong >Strongstrong > & < strong >Sturdystrong > < strong >shelvingstrong > Build plywood < strong >shelvesstrong > that not only look great but will stand up to heavy-duty loads for the long haul without < strong >saggingstrong > . Most of the storage and cabinet The amazing thing is how little sag first things to consider is the mate- projects I build have at least a cou- it takes before you begin to notice rial you use to build the < strong >shelvesstrong > . ple < strong >shelvesstrong > . The < strong >shelvesstrong > are used to it. All it takes is a sag of about 1/32" MATERIALS. For most of my projects, store everything from odds and for each foot of shelf length before I'll either use solid wood or ply- ends to heavy books and electron- it stands out like a sore thumb. wood over particle board or ics. And nothing's more disap- So any time you build a project medium-density fiberboard (MDF).

2 Pointing than seeing a shelf sag as with < strong >shelvesstrong > , it's important to keep And nine times out of ten, ply- soon as you start loading it up. strength in mind. And one of the wood will be my first choice. Now don't get me wrong. Plywood < strong >shelvingstrong > Fast Facts: There's nothing wrong with solid Always consider the expected load for a shelf when designing a project wood < strong >shelvesstrong > . They look great and The total load, how it's arranged, and how the shelf is reinforced all affect the they're < strong >Strongstrong > . But using only solid strength of a shelf wood can be expensive. Plus, solid You'll start to notice sag once it measures 1/32" for each foot of shelf length wood expands and contracts . The maximum shelf length to consider without any reinforcement is about 30" just another thing to think about The main ways to increase the strength of a shelf: when designing a project.

3 Widening (deepening) the shelf PLYWOOD < strong >shelvesstrong > . To avoid these Shortening the shelf problems, I turn to plywood. But Adding a hardwood strip on edge (roughly triples the strength) like other materials, even plywood Doubling the thickness (increases shelf strength by four) has its limitations. You can find out You can calculate the approximate sag of a shelf by use an online program: how much a plywood shelf will sag The Sagulator at using an interesting program, called The Sagulator (see Plywood < strong >shelvingstrong > 8 Fast Facts at left). This program con- siders the material, size and load- ing of a shelf and gives you a rough use a tongue and groove joint, like you see in the second photo from the top. The tongue and groove How-To: Add Strength idea of how much a shelf will sag.

4 Provides a mechanical lock, so GOOD. So what if you find your shelf isn't it's easy to keep the strip aligned up to the task? with the face of the shelf. For STRENGTHENING A SHELF. One of the many < strong >shelvesstrong > , this simple addi- simplest ways to minimize sag is to tion may be all it takes to elimi- make shorter < strong >shelvesstrong > or make them nate any noticeable sag. deeper. But that's not usually an TURN IT ON EDGE. But the best way to option since it affects the overall ensure a < strong >Strongstrong > shelf is to simply design and look of a project that I take that strip, widen it just a bit, may not want to change. and turn it on edge, like you see in GIVING PLYWOOD AN EDGE. Instead, I the main photo on the opposite Simple Edging. Although it adds a small amount of look for ways to give my plywood page.

5 Now there are a couple ways strength, the main purpose of a strip of thin edging a better edge. What do I mean by you can add a strip on edge (see is to cover up the plywood edges. that? Well, I almost always have to lower two photos at right). cover up the edge of plywood with The first way is to cut a rabbet in BETTER. thin strips of hardwood to hide the the hardwood strip and glue it in plys. You can see what I'm talking place. The other is to join the edging about in the top photo at right. to the shelf with a tongue and But hardwood edging doesn't groove joint. Both ways will triple always have to be thin and narrow. the strength of a shelf. Even though With a little thought and extra the tongue and groove joint is a little work, you can make that edging more work, it ensures the edging strip do so much more it can and shelf are aligned perfectly really add strength to the shelf.

6 Without much effort. To do this, but still maintain the HEAVY-DUTY DESIGNS. There are times Wide Hardwood Strip. To add strength, but still look of a thin shelf, I'll often use when strength is what matters maintain a thin edge, use a tongue and groove a wider hardwood strip. Gluing most. To see a couple different joint to add a wide hardwood strip to the shelf. on a wider strip can be a chal- ways to make a really < strong >Strongstrong > shelf, lenge. So when I do this, I like to check out the box below. W BEST. Heavy Loads: Beefing it Up Super- < strong >Strongstrong > < strong >shelvesstrong > . For very heavy loads, like encyclopedias and electronics, you might want to consider the < strong >shelvesstrong > shown above. They Turn it on Edge. Taking a wide hardwood strip and add more strength than what's shown in the margin.

7 Turning it on edge (top photo) significantly strength- Adding a pair of strips under the shelf along with an edging strip (left) ens the shelf without requiring a lot of additional helps reduce the sag to a fourth of a plywood shelf the same size. Want a work. Adding a tongue and groove joint (bottom simpler look with less joinery? You can get the same strength by doubling photo) adds just as much strength, but the joinery the thickness of the shelf and then gluing on a wide edging strip (right). makes aligning the edging and shelf a snap. 9.