Measure back opening (the plywood sits between the protruding outside edges of the sides that were formed from the rabbets that were previously milled, and fully overlaps the backs of the carcass top and bottom panels). Cut 1/4″ plywood to fit snugly. Even though I have a large cabinet saw equipped with ample outfeed support, I like to make the cross-cut first using a circular saw for a safer, more controlled operation, and then rip to width on a table saw. Be careful when cutting 1/4″ plywood on a table saw, as it can flex, allowing the material to rise above the blade which can cause a dangerous kickback. Use a slow feed rate, apply steady downward pressure when needed, and be sure to use your blade guard for this operation.
Plywood is an essential material for bookcases. It’s strong, affordable and good looking. There’s just one problem: those ugly edges. You can hide edges behind solid wood or moldings, but the quickest, easiest edge solution is a thin strip of wood veneer called “edge banding” ($6 for 25 ft. at home centers). The process couldn’t be simpler: You just iron on the adhesive-backed veneer and trim off the excess.
After investing a number of weekends building a nice table or chest, how are you going to finish it? Finishes beautify and protect the piece you’ve worked so hard to build so don’t cop out and do the “rub it with oil” thing. There are so many beautiful finishes that become second nature to work with. I use shellac 99% of the time. Once you get the feel down, it’s really quick to apply, very forgiving, easily repairable, and you never have to clean a brush (because it re-softens in alcohol)! There are other varnishes that provide good protection for outdoor use as well. I recommend picking up a good starter book, like Jeff Jewitt’s Hand Applied Finishes. It is simple and straightforward, without getting too far into minutiae.
Luckily, we have also managed to find a detailed video tutorial of the Barn door project that illustrates the process of building a Barn door of your own. The steps and instructions in the video tutorial are different from the source links listed above. Actually, you can make different types of designs for your Barn door depending on which one you can afford easily and DIY on your own.
You should also double-check the length of your all-thread rods. I'd dummy one up and try it out before cutting all of them. It needs to be just long enough to catch a couple of threads and snug down without punching out through the cap nut. The actual "cap" portion of cap nuts is fairly thin, and if the all-thread is even a bit too long it will punch through the end when you snug it up.
I was attracted to this page by the headboard. It looks great and it’s unique. I must disagree with the first sentence, that rustic is ‘in’ right now. I’m thinking, ‘It’s the great recession’. Any money I spend better get me the most refined thing I can afford. Kind of like how I believe that new store bought jeans with holes in them are going out of style like a cold cup of coffee.
Disclaimer: I've definitely taken a route that favors hand tools. More so than say, the 'modern' approach -- and it's mostly because, having used both awesome power tools, and awesome hand tools, I find that I enjoy the process of the work more with hand tools (I can actually chat with someone while I'm using hand tools -- not so much when I'm running a circular saw, router, sander, band saw, table saw, etc.) So, my take is going to be biased towards a more 'traditional' approach -- but the resources and people listed below are no strangers to modern tools either, and definitely make use of them when they choose.