Display Case Construction - Design and Acquisition
Some thought went into the design. I decided that I wanted the shelves to be two-tiered. I used some half-inch thick pieces of wood to experiment with spacing. The final verdict: each back shelf would sit 1 1/2 inch above the front shelf. These shelves would be three inches wide and the main shelves would be six inches wide.
To Home Depot I went to purchase lumber. I got two 4'x8' sheets of half-inch thick Birch plywood. I had them rip them into pieces of the following dimensions:
1 piece - 48"x49" - this will be the back of the case
11 pieces - 48"x6" - these are the outer frame and the 6" shelf inserts
8 pieces - 48"x3" - these are the recessed shelves
This was the same type of wood I had purchased for the decking of my railroad. Previously I had no issues with this wood warping. Therefore I was surprised to see all of the pieces cut from one of the sheets of plywood warp considerably within a couple of days of purchase.
A bit dismayed I searched for some solutions on-line, most of which involved wetting the wood and placing significant weight on it while it dried. These methods really did not interest me.
I purchased various metal clamps and four sturdy 3' x 1 1/2" x 1 1/2" pieces of Poplar.
Three of the pieces of Poplar I kept hole to clamp each shelf to during installation to keep them straight. The fourth piece of poplar I cut up into various lengths to used as spacers between the shelves.
Then I applied a healthy bead of wood glue to the outlined area and re-installed the shelf, clamping it securely in place. Once satisfied with the position of the piece being added, I drilled into each shelf using the pilot holes as guides and then screwed them in place.