John’s Jali
Back in August, we featured some modern DIY magic made by our clever customer John. Well, he’s been at it again – and he’s documented his latest project using Jali products so we can all see exactly how he did it. We think it’s fantastic, and that John should be really proud of what he’s achieved. It’s made the rest of us (okay, probably just me) feel just a teensy bit exhausted.
So here’s John’s account of his latest Jali-assisted triumph, while I go to have a little lie-down.
Before:
The room had unattractive shelves, messy cables and mismatched screens. Fixed wall brackets held the screens in place, so adjusting their height wasn’t a possibility. Worse still, removing the brackets would leave plenty of holes to fix.
We had already ordered the desktop and the small drawer unit. The desktop came with three pre-drilled 80mm cable holes. However, one sits directly over the drawers, making it difficult to use.
So, we had an idea. We ordered a set of Shelves, along with a range of MDF shapes in oak veneer. We also added more MDF pieces to use as frames and templates. The reason for each piece will become clear as the project unfolds.
Step 1
After disconnecting everything, and removing the old shelves…
First, we fixed a timber framework to the wall. As you can see, it also covers the existing holes left behind by the old TV brackets. For now, we’ll conveniently ignore the light switch—that’s a story for another day!
The framework supports the oak back panel and helps to carry the weight of the shelving unit. You can also see two of the pre-drilled 80mm cable holes. The hole on the left still has its plastic camt, while the one on the right is left open.
Step 2
Next, we used a couple of MDF templates as temporary supports while we fitted the base and side panels. We didn’t assemble the unit on the floor and lift it into place because it was simply too heavy. Instead, we built it one section at a time.
And at this point, found out the holes that I cut into the bottom shelf do not line up with those in the desktop, I missed by 19mm – the width of the side panel. There was a period of colourful language, then I calmed down and phoned Jali – who were very understanding, and didn’t laugh too much.. a replacement piece will arrive next week
(Big sigh of relief)
So, while waiting for the replacement, I used the old shelves as templates to get all the holes properly lined up – also to account for wavy walls – which can be seen in the top of the last picture – there’s a gap almost 20mm at the centre – while the sides are flush. I don’t think the original builders had a level or square…
A working template in place, on the temporary supports..
This shows the reason for the 80mm holes – the chrome tubes (table legs actually) are to run the cables, and the screens will hang from the shelf on the dramatic looking bracket.
You can see how flexible an old chipboard shelf is…..
And this is the replacement shelf, now with the holes in the correct place.
The sides go up…and in the centre, 3 more holes have appeared in the wall… there is a reason for this.
The top goes on… and the top rail is fixed to the wall – with some very large fixings.
And the temporary supports come down. The angle shaped patches on the frame are not supports – that’s just the light shining through the holes.
The uprights go in, and a substantial metal bracket will support the screens – the chrome tubes are back in place..this time – in the correct place.
And an oak panel (mdf veneer) goes on the back wall to cover the previous carnage.
Nearly Done
The screens are in place, and cables tidied away. The radio is back (most important).
I did treat myself to a second screen that matched the first one.
The centre section of the shelving now has a panel of mdf oak veneer. This is inserted to cover up the cables and power adapters for the 2 screens, as well as the top of the bracket. Its got a 38mm hole to make sure it can be removed easily – it was a very snug fit.
Same thing – just a different angle
Very Nearly Done
And it’s 99% finished. (Almost) all the sections have the back panels inserted (the light switch is still there 🙂
There’s a set of LED strip lights underneath to provide some decent work lighting – and very conveniently for me, the disastrous first attempt on the bottom shelf has been recycled to become a plinth to hide the light fittings – the power adapter for these also fits behind the centre section.
Done!
Wow. John has created a unique, bespoke unit that suits his office, and working requirements, perfectly. If you fancy designing something similar, this combination of shelving and mdf shapes is a genius idea. And don’t forget that we can cut holes in mdf shapes, from circles to triangles to squares and rectangles. Yes, even pentagons, which we’ve made for a customer recently, maybe with a Halloween-type application in mind?
We are very grateful to John for his brilliant narratives, photos and really useful insights into real, live, modern DIY projects. My own toolbox has now been liberated from the cupboard under the stairs, so watch this space!
