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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.