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This work is licensed under a Creative Commons Attribution-Noncommercial-Share Alike 3.0 License.
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WOODEN BOOTBLACK STAND
CONSTRUCTION AND
ASSEMBLY INSTRUCTIONS
Release Notes:
17 September 2010 - Initial Release
Designed and documented by
Andrew "Bootdog" Johnson
A1
A2
A3
A4
A5
A6
A7
B1
B2
C1
D1
E1
E2
F1
F2
A1
A2
A3
A4
A5
A6
A7
8-1/2" 2X4
9" 2X4
12" 2X4
20-1/2" 2X4
24" 2X4
33" 2X4
36" 2X4
C1
D1
E1
E2
32" 2X2
33" 1X2
12"X36" 3/4" PLYWOOD
1,2
B1
B2
12" 4X4
24" 4X4
36"X36" 3/4" PLYWOOD
1,2
G1
G2
1" WOOD SCREW
4
1" DRYWALL SCREW
5,6
F1
F2
5
8
" X 2" MENDING PLATE
CLOSED BAR HOLDER
3
PARTS LIST
G3
2-1/4" DRYWALL SCREW
5
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 G3
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.
NOTES
B2
Leg Construction: Step 1a
A4
A4
G3
G3
G3
G3
Attach a 20-1/2" 2x4 (A4) to two sides of a 24" 4x4 (B2) with two 2-1/4" screws
(G3) 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.
8-1/2"
A4
Leg Construction: Step 1b
F1
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).
3-3/4"
A4
A4
Leg Construction: Step 1c
G3
G3
Attach a 24" 2x4 (A5) to both 20-1/2" 2x4s (A4) with three 2-1/4" screws (G3) 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.
8-1/2"
A4
G3
G3
G3
G3
A5
A5
EQ
EQ
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.
A5
Right Front Leg Construction: Step 2a
On one leg, attach a 8-1/2" 2x4 (A1) to the left-hand 24" 2x4 (A5) with two 2-1/4"
screws (G3). 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.
4-1/4"
G3
G3
A1
2"
Right Front Leg Construction: Step 2b
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).
2-3/4"
G1
A1
F1
Right Front Leg Construction: Step 2c
Attach a 12" 2x4 (A3) to the 8-1/2" 2x4 (A1) with two 2-1/4" screws (G3). 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.
4-1/2"
G3
A1
A3
G3
2"
1-3/4"
A5
Right Front Leg Const.: Step 2 Complete
The right front leg is now complete
A5
Left Front Leg Construction: Step 3a
On one leg, attach a 8-1/2" 2x4 (A1) to the right-hand 24" 2x4 (A5) with two
2-1/4" screws (G3). 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.
4-1/4"
G3
G3
A1
2"
Left Front Leg Construction: Step 3b
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).
2-3/4"
G1
A1
F1
Left Front Leg Construction: Step 3c
Attach a 12" 2x4 (A3) to the 8-1/2" 2x4 (A1) with two 2-1/4" screws (G3). 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.
4-1/2"
G3
A1
A3
G3
2"
1-3/4"
A5
Left Front Leg Const.: Step 3 Complete
The left front leg is now complete
Deck Construction: Step 4a
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.
G3
A7
G3
A6
A7
1-1/2"
Deck Construction: Step 4b
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.
G3
A7
A6
A7
1-1/2"
G3
Deck Construction: Step 4c
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.
G3
A6
1-1/2"
G3
A6
A6
EQ
EQ
EQ
EQ
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
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.
E2
G2
Deck Construction: Step 4f
C1
G3
C1
C1
Attach three 32" 2x2s (C1) centered to three edges of the deck with four 2-1/4"
screws (G3) each. Space the G3s evenly along the C1, making sure to avoid
dirving the screws through the previously placed 1" screws (G2).
Deck Construction: Step 4g
G2
D1
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)
12"
Deck Construction: Step 4 Complete
The deck is now complete
Step Construction: Step 5a
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.
G3
A7
G3
A2
A7
1-1/2"
Step Construction: Step 5b
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.
G3
A7
A2
A7
1-1/2"
G3
Step Construction: Step 5c
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.
G3
A2
1-1/2"
G3A7
EQ
EQ
A7
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
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.
E1
G2
Step Construction: Step 5f
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 (G3) 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.
G3
B1
B1
1-1/2"
1-1/2"
1-1/2"
Step Construction: Step 5g
Attach a 36" 2x4s (A7) to the front of the 4x4 legs (B1), using four 2-1/4" screws
(G3). Offset the screws similarly to the screws attaching the B1 to the frame.
G3
B1
B1
1-1/2"
1-1/2"
A7
Step Construction: Step 5h
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.
G2
A7
18"
A7
F2
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.
Recommended