Step 11: Size the shelf boards.

crosscutting the shelf board with a circular saw
Photo: Ryan Benyi
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The shelf is made up of two boards, one shorter than the other to create notches that fit against the rungs. Rest the top board in place on the stretcher rungs, one end aligned with the outside of the frame. At the other end, mark the board where it extends past the rung. Use a rafter square to guide your circular saw, as shown, to make the crosscut. Mark the bottom shelf board to fit between the rungs, and crosscut it to length.
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    Tools List

    • 30-foot tape measure
      measuring tape
    • hand clamps
      clamps
    • straightedge guide
      straightedge
    • Painter's Tape
      painter's tape
    • circular saw
      circular saw
    • random orbit sander
      random-orbit sander with 100-, 120-, and 180-grit discs
    • drill
      drill/driver
    • Lag-screw driver bit
      driver bit
    • belt
      belt
    • Rafter Square
      rafter square
    • 1/8-inch bit with combination countersink
      -inch bit with countersink
    • combination square
      combination square

    Shopping List

    Butcher-block countertop.
    Get one 25-by-96-inch piece IKEA.
    (Note: The size of the gas pipe has been corrected from the print edition.)

    ½-inch iron threaded pipe.
    Get one 36-incher, six 18-inchers, two 12-inchers, four 6-inchers, six 5-inchers, two 4½-inchers, and six 2-inchers.

    ½-inch iron threaded pipe elbows. Get two.

    ½-inch iron threaded pipe flanges. Get eight.

    ½-inch iron threaded pipe tees. Get 14.

    1x10 oak board. Get one 8-footer.

    Wood glue

    1-inch No. 10 flat-head wood screws for securing the flanges and shelf boards casters. Get four.

    1-inch No. 10 pan-head wood screws for securing the casters

    Beeswax

    Mineral oil