How to Cut an IKEA Billy Shelf
IKEA Billy shelves are made from particleboard covered in a plastic laminate. Cutting such material requires care and attention to detail because plastic laminates chip easily, potentially leaving rough, unattractive edges. The popularity of "hacking" IKEA furniture to create bespoke items such as mirrored tables and impressive pet homes has led to increased customization of Billy bookcases and shelving. Does this Spark an idea?
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Instructions
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Rest the shelf on a smooth, flat surface with plenty of room around it in which to work.
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Orientate the shelf correctly before making any cut marks. For example, if you intend to make a cut in from the front of the shelf, ensure that the front is facing you before you commence marking out. Use a pencil to roughly mark the positions of the intended cuts on both sides of the shelf.
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Lay masking tape along the routes of all the intended cuts. Press the tape firmly down onto the laminate and rub it flat with your hand. The objective is to obtain a good seal between the tape and the shelf, with no air bubbles.
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Mark the precise positions of the cuts on top of the masking tape. Again, use a pencil to make the marks, erasing any mistakes as you progress. The result should be clearly visible and precisely aligned guidelines to follow.
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Score along the cut marks with a sharp knife. Cut as deeply as possible to break through the laminate layer. This greatly reduces the chances of the edge chipping as you cut it.
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Attach a fine-toothed blade, designed for use with wood or multiple materials, to a jig saw. Attachment methods vary according to make and model, but many require you to loosen a retaining screw, insert the blade into a guide slot and retighten the retainer.
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Place the shelf, cut face down, so that the area to be cut overhangs an open space of sufficient depth to allow the jigsaw blade to cut through the particleboard without hitting your work surface. Rest the jigsaw on the shelf, with the sole plate firmly against the shelf surface and the blade just short of touching the edge of the shelf. Press the trigger to start the saw. Secure the shelf in position by holding it, placing a heavy weight on the free end or asking an assistant to hold it for you.
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Rest the leading edge of the jigsaw on the shelf, with the sole plate firmly against the shelf surface and the blade just short of touching the edge of the shelf. Press the trigger to start the saw.
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Push the jigsaw forward in a slow and fluid motion, without forcing it into the wood. Allow the blade to do the work for you. Follow the lines marked on the masking tape by observing them through the guide slot in the front of the sole plate.
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Remove the masking tape from the shelf by first lifting a corner and then peeling if off, starting on the edge farthest away from the cut. Smooth the edges of the cut using sandpaper.
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Tips & Warnings
Use a pencil for marking on the shelf laminate. Pencil lines are easily erased if you make a mistake, whereas alcohol pens may permanently stain the surface.
Remove the masking tape by working from the back edge and toward the cut edge to get the best results. Peeling from the cut edge toward the back of the tape may lift small pieces of laminate away from the cut, leaving an unsightly result.
Place the shelf cut face down before cutting because jigsaws cut from the bottom up. The bottom side is less likely to be chipped by the action of the blade and thus has a cleaner finish.
Forcing a blade into the wood may cause it to bend and cut a curved line rather than a straight one.
Excessive force may cause a blade to snap.
References
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