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How to upcycle a flat pack bookcase

Bookcase styled with home decor objects.

Overview

Upcycle a flat pack bookcase into designer furniture with plywood cladding and chalk paint.

Transform a basic bookcase with chic curved cladding using this flat pack furniture hack. Create a cutout and side pieces from wallet-friendly plywood, attach with glue and screws, then sand and finish with Dulux chalk paint for designer furniture on a D.I.Y. budget.

Tips to get started

1. The five-shelf bookcase we’ve used is 1800mm high, 800mm wide and 280mm deep, but you can adjust the measurements to fit any size.

2. Using one sheet of plywood minimises wastage and is kinder to the budget. It creates a join halfway down one side of the bookcase, but this becomes invisible when filled and painted.

3. For easier handling, have the plywood cut in store to 1800mm long.  

Safety tip: Always wear the appropriate safety equipment (safety glasses, ear muffs and a mask, for example) and always follow the instructions for the product or equipment.

Bookcase line drawing with dimensions.

Steps

1Assemble the bookcase

Following the instructions, assemble the bookcase, keeping adjustable shelves and wall anchors to install later. Apply adhesive along raw edges, tighten fasteners using a screwdriver and hold plastic joiners to the backing with cloth tape while positioning them.
A white flat pack bookcase being assembled with a screwdriver.

2Cut the plywood

Position the plywood sheet on sawhorses. Use a framing square to mark the front, side A and side B pieces (see diagrams, above), then cut using a jigsaw with a clamped straightedge.
A piece of plywood being cut with a jigsaw.

3Mark the arches

Mark cutting lines and a centre line on the front cladding (see diagrams, above), and draw arches using a framing square positioned on the centre line with a screw pivot in the inner corner.
Framing square being used to draw arches on plywood.

4Make the cut-out

Drill a 10mm starter hole inside an arch. Cut with a jigsaw, clamping the centre to prevent it from falling through. Sand the cladding to smooth all over and remove breakout along cut edges.
Starter hole drilled in plywood to cut arch.

5Attach the cladding

Apply adhesive to cladding and clamp in place. Use a countersinking bit to predrill into the corners, securing with 20mm screws. Smooth over the screws and side B join with filler, leaving to dry. Sand off excess filler and wipe with a damp cloth.
Plywood cladding clamped to bookcase being screwed into place.

6Sand and paint

Mask along the front of the fixed shelves. Use a mini roller to apply primer and two coats of chalk paint to the cladding, leaving to dry after each coat. Secure bookcase to the wall with anchors and install adjustable shelves.
Primer being applied to plywood cladding using a paint roller.

7Keep in mind…

  • When using power tools, always wear the recommended safety gear.
  • Wear a mask and work in a well-ventilated area when cutting and sanding plywood and painting.
  • Enlist a second pair of hands to move the heavy bookcase. Ensure it is safely secured to the wall and do not climb on it.
  • Before drilling into walls, use a stud finder to check for wiring or pipework, and turn off the power before working. If unsure, call a professional.
  • Keep all paint and chemicals out of reach of children and pets.
  • Paint colours may vary on application.
  • *Timbers vary by state and territory; contact your local store for further information.

8For more easy D.I.Y. updates…

Check out our furniture & upcycling projects.

 

Photo Credit: Jonny Valiant, Natasha Dickins

Health & Safety

Asbestos, lead-based paints and copper chromium arsenic (CCA) treated timber are health hazards you need to look out for when renovating older homes. These substances can easily be disturbed when renovating and exposure to them can cause a range of life-threatening diseases and conditions including cancer. For information on the dangers of asbestos, lead-based paint and CCA treated timber and tips for dealing with these materials contact your local council's Environmental Health Officer or visit our Health & Safety page.

When following our advice in our D.I.Y. videos, make sure you use all equipment, including PPE, safely by following the manufacturer’s instructions. Check that the equipment is suitable for the task and that PPE fits properly. If you are unsure, hire an expert to do the job or talk to a Bunnings Team Member.