Spiral Wall Shelf, the children's books are all drastically different sizes. Putting them on a shelf seems almost pointless because they're either too big and don't fit or they're too small and waste space (plus they're minutes away from being thrown on the floor anyway).
Instead of worrying about this, I decided to embrace it and build a bookshelf where each shelf was different.
This Nautilus-inspired bookshelf isn't meant to be efficient or to pack books neatly, it's about eagerly and enthusiastically embracing the chaos that is children's books.
The bookcase is made of 15 sheets of maple plywood, jet machined, laminated together, stained and finished.
Step 1: Inspiration
Overall, I knew I wanted a bookcase with variable-sized shelves. However, I got stuck on things that looked like rectilinear shelves that were off-center or crooked.
I asked my 5-year-old daughter to draw the bookshelf she wanted and she drew a spiral. Perfect!
Step 2: Draw the shape

I used AutoCAD LT to draw the shapes.
First, I drew a logarithmic spiral and then cut it into regular sections while consulting pictures of nautilus shells to get the proportions roughly correct.
Near the center of the spiral, the sections sweep twice the angle because I didn't want the center shelves to become too small.
Then I offset the 0.75" spiral as a shelf thickness that seemed about right.
The overall scale of the shelves is such that two profiles can be cut from a single 4'x 8' sheet of plywood.
This makes the dimensions approximately 46" x 36".
Files attached both the AutoCAD LT drawing and a .DXF.
Step 3: Machine-cut layers of wood





I used 0.75” maple grade plywood and cut the profiles at the Pier 9Omax Jet Machining Center. I cut the plywood over the water so it wouldn't get completely soaked.
I cut 15 profiles from 8 pieces of plywood.
Profile 16 was a solid sketch of the shelf intended to be a backing that I ultimately decided not to use.
Each profile took almost 30 minutes to cut, so I monopolized the plane for 8 hours with this project.
Step 4: Reclaimed Wood


The very nature of my process generated a lot of waste wood.
With so many other projects happening on the pier, fortunately much of this was reused.
Step 5: 15 Stacked Layers



Here are all 15 layers stacked together.
The discoloration along the cut surfaces is maroon from the jet that has been forced into the wood, probably when the jet passes over its steel slats.
Moderate sanding did not remove the marks, so I decided to ignore them.
Step 6: First Layer


I wanted the exposed face to be free of marks, including nail holes.
To accomplish this, I glued it to the second layer and held the two pieces together with just about every clamp in the store.
Step 7: Inner Layers


The inner layers are maThey are held together with glue and nails.
Since each layer is the same shape, I aligned them by feel along the edges.
Step 8: Final Coat



Just like the first layer, I wanted the final layer to be free of marks, so both sides were intact.
I glued the final layer and, again, used all the clamps in the store that were big enough.
Step 9: Sand



Using 80 grit sandpaper, I roughly sanded the shelf until the individual layers were level.
Where I could, I used a belt sander, and on internal areas, a random orbital sander or sanding block.
I only sanded the larger cavities, the smaller ones were too difficult to access and are not easily visible.
Step 10: Fill the holes




Many holes in the plywood were exposed.
I filled them with wood filler and continued sanding.
Step 11: Sand until smooth


After filling the voids, I sanded with 100, 200, and 400 grit sandpaper.
This step literally took weeks, as I would spend 30 minutes sanding a couple of times a week.
Step 12: Staining






We tried a few stains and chose lead-colored Miniwax Classic.
At first I thought it wouldn't stain the shelf, but the gray stain looked good and did a great job covering the marks.
Step 13: Finish

With so much surface area and the possibility of many drops, I sought professional help to finish the shelf. I covered the shelf with a water-based acrylic lacquer.
Step 14: Everything Perfect






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