Floating Nightstand

Instructions

This project was designed in Fusion 360. The design file is attached in addition to the cut-ready files. More pictures on the Shaper Community Forum: https://community.shapertools.com/t/floating-nightstands/11772 1. Mill the lumber to 36mm thick (or thicker and adjust SVG) 2. Cut to the rectangular size on the table/miter saw 3. Mount the shelf into Shaper Workstation so its rear is facing up. Make a grid and load the shelf rear SVG file. Pocket the 1/4" deep squares for the wall brackets, and cut the 11/16" holes as deep as possible to serve as a starting point for the drill to go the rest of the way and remain straight 4. Drill the 11/16" rear holes for the bracket to a depth of 6.5" from the rear face of the shelf using an auger bit and ideally a drill alignment jig. 5. Use Shaper Plate or ShaperTape on the rear of the shelf to pocket/drill the bracket bolt holes and countersinks into the bottom of the shelf. The drill should penetrate into the cavity that was made for the brackets. This is where machine screws will screw into shelf brackets. 6. Wrap some blue tape around the brackets about a half inch from the end, so you can mark the hole locations you just drilled onto the brackets. 7. Push the brackets in with string around two of the wall mounting holes on each so they can be pulled back out. Ensure they fit all the way and are aligned with the holes you just drilled from the bottom face. 8. Remove one of the brackets from the holes. 9. Mount the ONE removed bracket to a stud in the wall (this design assumes you have standard 16" stud spacing). Use only two screws for now as it will need to be removed again. The other bracket should still be in the rear of the shelf (with string through two of the holes so it can be removed). Install the center-locating punches in the other two holes of that bracket. 10. Ensure the shelf is level (put a level on top), and slide it onto the one bracket that is temporarily attached to the wall and press against the wall to mark where the other bracket needs to be screwed in so everything aligns perfectly. 11. Pull the shelf away from the wall and remove the bracket that is in the shelf. Screw it to the other stud at the marked location from the center-locating punches. 12. Slide the self onto the two brackets and make sure it can go all the way to wall. 13. Using a marker through the countersunk bolt holes that you cut into the bottom of the shelf, mark on the blue tape where the fixing hole should be drilled/tapped into the brackets. 14. Remove the shelf from the wall 15. Remove the brackets from the wall. Cut the provided support semicircle jig to hold the bracket in a drill press. Clamp it down and drill a 5mm hole for the bolt, about half way through the diameter of the bracket rod. 16. Tap M6 threads into the rods. 17. Slide the brackets into the shelf (again with string so you can remove it) and ensure the set screws all still line up properly. 18. Remove the rods. 19. Use Shaper Plate to add the corner rounds: https://hub.shapertools.com/creators/59b9b947291ebbfa71254b56/shares/6351788e91733509027f62ba 20. Add the cable passthru, also using Shaper Plate. 21. Bend the brass rods to the appropriate lengths for your shelf size. 21. On the top of the shelf, use Shaper plate to add the holes for the 1/4" rods. Your hole positions may need to be tweaked to perfectly match the rod lengths since it's hard to bend them to perfectly similar lengths. 22. Use a trim router to apply 1/8" round-over to the edges of the shelf 23. Sand and finish the shelf 24. Reinstall the wall brackets, this time using all four screws. 25. Slide the shelf on and install set screws.