Creative Woodworks & crafts 2003-06, страница 58

continued from page 57

sure to double check before you cut.

You need to set a stop to cut the 3/4" thick base and the 1/2" thick top to the same length. Cut the base 20" long x 12" wide. Cut the top 20" long x 11-1/2" wide. This 11-1/2" measurement is a little wider than necessary, but you will finish to the correct width later. Set the top aside for finishing later.

Apply edging to the front edge of the base. Then cut the 1/2" wide x 3/8" deep rabbet in each end of the base. Since you want the grooves for the center divider to be the same distance from the ends in both the base and the top. you need to set up a stop before cutting the center groove. Cut the 1/2" wide x 3/8" deep groove in the base (see Fig. 4). With the stop still in place, reset the cutting depth to 1 /8" deep, and cut the corresponding groove in the 1/2" plywood top. Finally, cut the 1/2" wide x 1/8" deep rabbet in each end of the top for the sides.

Before you cut the 1 /2" plywood top to the right width, fit it to the sides and center divider. First cut the front edge to 45°, to match the bevel. With the rabbets and groove cut into the fop, you can dry fit the top to the sides. Make sure the front edge is flush with the front edge of the sides, mark and cut the top to 11-1/8" wide, so it is flush with the rear edge of the sides and center divider.

These rabbets in the base and the top are for the back panels to fit into. Cut the 1/4" wide x 1/4" deep rabbet on the back edge of the base. Cut the 1 /4" wide x 1 /8" deep rabbet in the rear edge of the top.

Eliminating the mess of cords and phone books

The cord storage is nothing more than a divider that will keep the cords in one area as you push them into the case.

Cut o piece of wood 3/4" x 3/4" x 7" long for the storage divider cleat. Cut a piece of 1/4" plywood 7" wide x 4-1/4" high for the storage divider. Glue and clamp the storage divider to the divider cleat. Set this assembled piece aside for later.

The cutout on the front edge of your tray does not have to match mine exactly. However, it should be cut in far enough to allow you to easily grip the phone book and pull it out. Cut two pieces of 1/2" x 3/4" x 11" long for the supports. The 1/4" plywood tray is cut 11-1/4" long x 11-1/2" wide. Use a jig saw, coping saw or scroll saw to cut the pattern into the front edge of the tray.

Putting It All Together

Referring to Fig. 5, start assembly by gluing and clamping the center divider into the center groove. Make sure the front edge is flush with the front edge of the base and is square with the base. The shelf supports, the shelf, and cord storage divider can also be glued in at this time. To provide clearance for the hinges, make sure both the shelf supports are set back 1/2" from the front edge of the base. The right support should be glued to the base and center divider. The left support can be glued to the base flush with the inside edge of the rabbet. Do not get glue into the rabbet and make sure the support does not hang over into the rabbet. After the glue for the supports has set, glue in tray, with the front of the tray flush with the front of the supports. The cord storage divider should be glued in 1-1/2" from the back edge of the base.

Once the glue has set, there are a couple of things you need to do before putting on the top. You should put a finish, of varnish or shellac, on all the inner pieces, such as the shelf, top side of the base, and sides of the center divider. Also, install the hinges to the base for the two front doors (see Fig. 6).

Dry fit everything before gluing the top and ends on. The end should fit flush with the front and rear edges of the base, and the top should fit flush with the front edge.

Glue the sides into the rabbets on the top and the base. Make sure the front edges of the sides fit flush with the front

58 • Creative Woodworks & Crafts June 2003

edge of the base and the bevel on the top fits the bevel on the front of the sides and center divider.

For the rear panel, cut a piece of 1/4" plywood 4-3/4" wide x 11-9/16" long and glue into the rabbets previously cut in the top and base.

Cut a piece of 1/4" plywood 7" long x 4-3/4" wide for the rear door of the cord storage area. After cutting to size, use a 3/4"-Dia. Forstner bit to drill the access holes for the cords to pass through (see Fig. 7). After drilling the holes, cut the slots to the edges using a band saw or jig saw. Drill a 5/32" hole for the screw in the door as shown. The door can have a loose fit to make it easy to open and close.

Apply edging here

Fig. 1. Glue the edging in place where the plywood will be exposed.

Fig. 2. Cut the two side pieces and center divider to shape.

Groove for the center divider

Fig. 3. Cut the 45° angle on the side pieces and center divider with a power miter saw.

Fig. 4. Cut the groove for the center divider and the rabbets for the side pieces in both the top and base pieces.

Fig. 5. Begin assembly.

Fig. 5. Begin assembly.

1-1/0"

Fig. 6. Apply finish to the inside of the telephone center before attaching the top and install the hinges.

1-1/0"

Fig. 6. Apply finish to the inside of the telephone center before attaching the top and install the hinges.

2"

Fig. 7. Cut the rear door to shape.

2"

Fig. 6. Make the board to receive

the latch for the rear door.