WOODEN BOOTBLACK STAND CONSTRUCTION AND ASSEMBLY INSTRUCTIONS Designed and documented by Andrew "Bootdog" Johnson Release Notes: 17 September 2010 - Initial Release This work is licensed under a Creative Commons Attribution-Noncommercial-Share Alike 3.0 License. Please visit http://www.creativecommons.org/ for more information.
PARTS LIST A1 A2 A3 A4 A5 A6 A7 B1 B2 C1 D1 F2 F1 E1 E2 A1 8-1/2" 2X4 B1 12" 4X4 F1 5 8 " X 2" MENDING PLATE A2 9" 2X4 B2 24" 4X4 F2 CLOSED BAR HOLDER 3 A3 12" 2X4 C1 32" 2X2 G1 1" WOOD SCREW 4 A4 20-1/2" 2X4 D1 33" 1X2 G2 1" DRYWALL SCREW 5,6 A5 24" 2X4 2-1/4" DRYWALL SCREW 5 A6 33" 2X4 E1 12"X36" 3/4" PLYWOOD 1,2 A7 36" 2X4 E2 36"X36" 3/4" PLYWOOD 1,2
NOTES 1 1/2" plywood is recommended for reduced weight and materials costs, but 3/4" plywood or 1/2" or 3/4" multi-density fiberboard (MDF) may also be used. Note that MDF is heavier than plywood and the edges of the board will wear more quickly. Likewise, 3/4" plywood is heavier than 1/2" plywood and significantly more expensive. However, 3/4" plywood and MDF both can support more weight than their 1/2" counterparts. 1/2" stock should be sufficient to support most people, but no assertion regarding actual safe weight loading for any material is implied by this document. 2 Plywood is graded by letter codes. "A" grade plywood is virtually defect free, while "D" grade possesses large knotholes and voids. Plywood is graded on both sides. BCX plywood is probably sufficient for most stand construction (the X designation represents exterior grade). CDX plywood may be acceptable as well. Remember to determine which side of the plywood is the higher grade and turn that side up when attaching it to the deck. 3 Closed bar holder is made by National Manufacturing (NM Stock Number N100-743, UPC Code 038613100749) and may not be available at local retail hardware stores. Several online merchants sell the item. 4 Appropriate wood screws (G1) may be included with the mending plates (F1). 5 Use coarse thread drywall screws for G2 and 6 If 3/4" MDF or plywood is used (see note 1 above), then the 1" screws should be replaced with 1-1/4" screws to ensure that the plywood is securely attached to the frame. The chair rail should still be attached using 1" screws to avoid having the points of the screws protrude through the underside of the deck.
Leg Construction: Step 1a B2 A4 A4 8-1/2" Attach a 20-1/2" 2x4 (A4) to two sides of a 24" 4x4 (B2) with two 2-1/4" screws () for each centered on the 2x4 approximately 8-1/2" apart. The bottom of the 2x4s should be flush with the bottom of the 4x4.
Leg Construction: Step 1b A4 A4 F1 3-3/4" F1 G1 G1 Attach a mending plate (F1) to both 2x4s (A4) with the center of the plate approximately 3.75 inches below the top edge of the 2x4 using 1" wood screws (G1).
Leg Construction: Step 1c A4 A4 A5 A5 EQ EQ 8-1/2" Attach a 24" 2x4 (A5) to both 20-1/2" 2x4s (A4) with three 2-1/4" screws () for each centered on the 20-1/2" 2x4 approximately 8-1/2" apart. The bottom of the 2x4s should be flush with the bottom of the other 2x4s and 4x4.
Leg Construction: Step 1 Complete Repeat Steps 1a-1c to make a total of four legs. Two legs are complete at this point and the other two will be used in Steps 2 and 3 to make the front legs.
Right Front Leg Construction: Step 2a A5 A1 4-1/4" 2" On one leg, attach a 8-1/2" 2x4 (A1) to the left-hand 24" 2x4 (A5) with two 2-1/4" screws (). The bottom of the 2x4 should be flush with the bottom of the leg. The screws should be centered on the 8-1/2" 2x4, spaced about 4-1/4" apart vertically, and offset horizontally by about 1 inch to each side to avoid hitting other screws.
Right Front Leg Construction: Step 2b A1 2-3/4" G1 F1 Attach a mending plate (F1) to the 8-1/2" 2x4 (A1) with the center of the plate approximately 2.75 inches below the top edge of the 2x4 using 1" wood screws (G1).
Right Front Leg Construction: Step 2c A5 A1 A3 4-1/2" 1-3/4" 2" Attach a 12" 2x4 (A3) to the 8-1/2" 2x4 (A1) with two 2-1/4" screws (). The bottom of the 2x4 should be flush with the bottom of the leg. The screws should be centered vertically on the 8-1/2" 2x4, spaced about 4" apart vertically, and centered horizontally to avoid hitting other screws. Note that the lowest screw attaching the 24" 2x4 (A5) to the leg is located at approximately 1-3/4" above the floor level, while the lower screw attaching the 12" 2x4 (A3) is 2" above the floor level. If necessary, the lower screw can be moved up slightly to avoid hitting the other screw.
Right Front Leg Const.: Step 2 Complete The right front leg is now complete
Left Front Leg Construction: Step 3a A5 A1 4-1/4" 2" On one leg, attach a 8-1/2" 2x4 (A1) to the right-hand 24" 2x4 (A5) with two 2-1/4" screws (). The bottom of the 2x4 should be flush with the bottom of the leg. The screws should be centered on the 8-1/2" 2x4, spaced about 4-1/4" apart vertically, and offset horizontally by about 1 inch to each side to avoid hitting other screws.
Left Front Leg Construction: Step 3b A1 2-3/4" G1 F1 Attach a mending plate (F1) to the 8-1/2" 2x4 (A1) with the center of the plate approximately 2.75 inches below the top edge of the 2x4 using 1" wood screws (G1).
Left Front Leg Construction: Step 3c A5 A1 A3 1-3/4" 2" 4-1/2" Attach a 12" 2x4 (A3) to the 8-1/2" 2x4 (A1) with two 2-1/4" screws (). The bottom of the 2x4 should be flush with the bottom of the leg. The screws should be centered vertically on the 8-1/2" 2x4, spaced about 4" apart vertically, and centered horizontally to avoid hitting other screws. Note that the lowest screw attaching the 24" 2x4 (A5) to the leg is located at approximately 1-3/4" above the floor level, while the lower screw attaching the 12" 2x4 (A3) is 2" above the floor level. If necessary, the lower screw can be moved up slightly to avoid hitting the other screw.
Left Front Leg Const.: Step 3 Complete The left front leg is now complete
Deck Construction: Step 4a A7 A6 1-1/2" A7 Assembly of the deck frame should be performed on a flat, even surface to ensure that one face of the frame is completely flat. This will make attaching the plywood easier and produce a cleaner final appearance. A hard floor, large (at least 48" sqaure) work bench, or large piece of plywood is ideal. Attach a 36" 2x4 (A7) to each end of a 33" 2x4 (A6) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Deck Construction: Step 4b A7 A6 A7 1-1/2" Attach the other ends of the 36" 2x4s (A7) to each end of a 33" 2x4 (A6) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Deck Construction: Step 4c A6 EQ A6 EQ EQ A6 EQ 1-1/2" Attach a 33" 2x4 (A6) to the midpoint of the previously placed 33" 2x4s (A6s) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Deck Construction: Step 4d Flip the frame over to the other side; this will place the flatter side of the frame up, making contact with the plywood more even.
Deck Construction: Step 4e G2 E2 Place the 36" square sheet of 1/2" plywood (E2) onto the frame. Using 1" screws (G2) attach the plywood to the deck frame. It is recommended that two adjacent corners be secured with one screw each, then the frame be squared to match the plywood and the other two corners attached, followed by the screws evenly spaced along the sides. Take care to position each screw as close to the center line of the 2x4 as possible. Draw a line showing the position of the centerline of the cross beam 2x4 to aid in positioning the three screws along the cross beam. A framing square or straight edge can be used along with the position of the screws driven in Step 4c to position the line accurately.
Deck Construction: Step 4f C1 C1 C1 Attach three 32" 2x2s (C1) centered to three edges of the deck with four 2-1/4" screws () each. Space the s evenly along the C1, making sure to avoid dirving the screws through the previously placed 1" screws (G2).
Deck Construction: Step 4g D1 G2 12" Attach one 33" 1x2 (D1) to the deck with the centerline approximately 12" away from the back edge of the deck, using four 1" screws (G2)
Deck Construction: Step 4 Complete The deck is now complete
Step Construction: Step 5a A2 A7 1-1/2" A7 Similarly to the deck frame, assembly of the step frame should be performed on a flat, even surface to ensure that one face of the frame is completely flat. This will make attaching the plywood easier and produce a cleaner final appearance. A hard floor, large (at least 48" sqaure) work bench, or large piece of plywood is ideal. Attach a 36" 2x4 (A7) to each end of a 9" 2x4 (A2) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Step Construction: Step 5b A7 A7 A2 1-1/2" Attach the other ends of the 36" 2x4s (A7) to each end of a 9" 2x4 (A2) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Step Construction: Step 5c EQ A2 EQ A7 A7 1-1/2" Attach a 9" 2x4 (A2) to the midpoint of the previously placed 36" 2x4s (A7s) with two 2-1/4" screws for each end, spaced about 1-1/2" apart.
Step Construction: Step 5d Flip the frame over to the other side; this will place the flatter side of the frame up, making contact with the plywood more even.
Step Construction: Step 5e E1 G2 Place the 12"x36" sheet of 1/2" plywood (E1) onto the frame. Using 1" screws (G2) attach the plywood to the deck frame. It is recommended that two adjacent corners be secured with one screw each, then the frame be squared to match the plywood and the other two corners attached, followed by the screws evenly spaced along the sides. Take care to position each screw as close to the center line of the 2x4 as possible.
Step Construction: Step 5f 1-1/2" 1-1/2" 1-1/2" B1 B1 Attach two 12" 4x4s (B1s) to the front corners of the deck, squared to the corners of the horizontal 2x4s (A2 and A7). Attach the B1s to the frame using four 2-1/4" screws () on each. For added stability of the joint, offset the screws horizontally by 3/4" from the center line of the 4x4 and vertically by 3/4" from the centerline of the 2x4, making sure to orient the screws such that they don't run into one another in the wood.
Step Construction: Step 5g B1 1-1/2" 1-1/2" B1 A7 Attach a 36" 2x4s (A7) to the front of the 4x4 legs (B1), using four 2-1/4" screws (). Offset the screws similarly to the screws attaching the B1 to the frame.
Step Construction: Step 5h 18" A7 G2 A7 F2 Attach the four brackets (F2) to the two 36" 2x4s (A7) using 1" drywall screws (G2), centering the brackets vertically on the 2x4s. Space the brackets horizontally 18" on center. Take care not to over-tighten the screws; the brackets should allow the 2x4 footrests to slide smoothly into place without being too loose.
Step Construction: Step 5 Complete The step is now complete
Stand Assembly: Step 6a Position the legs in a square as shown, with the 4x4s oriented toward the inside of the square. The individual legs should be spaced with the centers of the 4x4s approximately 30" apart. The construction of the stand is such that the deck can temporarily rest on top of legs that are slightly out of position while the other legs are aligned.
Stand Assembly: Step 6b Lower the deck onto the legs, sliding the 2x4 rails into the cradles made by the 4x4s and 2x4s. The legs should be stable enough to support the deck while the deck and the legs are aligned. Check to make sure that all legs are upright; legs that are tilted can be adjusted with a gentle kick.
Stand Assembly: Step 6c Lower the step into the cradles on the front legs. It may be necessary to shift the bottoms of the legs slightly inward to get the step properly seated in the cradles. Remember to shift the legs back to their upright position afterwards. If the step does not seat completely into the cradles, a small amount of force applied to the deck of the step by a foot should seat it firmly.
Stand Assembly: Step 6d Insert the footfrests (A7) into the brackets on the front of the step. The brackets should slide easily into and out of the brackets. If the brackets are too tight, back the attaching screws off a quarter turn and reevaluate the tightness of the fit.
Stand Assembly: Step 6 Complete The stand is complete.