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building the The organizer starts out by building a large plywood box (Figure 1). The first step is to cut the top, bottom, and sides. Then, you're ready for the tongue and groove joinery, which can all be cut on your table saw. The Joinery. When I cut this type of joinery, I like to start with the grooves and dadoes. Then I can sneak up on the thickness of the tongues until they fit snugly. The front and back will fit flush with the outside edges of the other parts on all four sides. So, you'll want to make sure the inside edges of the dadoes and grooves line up with the thickness of the front and back (Figures la and lb). And be aware that there are no dadoes in the top and bottom. These parts only get grooves along their outside edges. Once you have the grooves and dadoes cut, you can start working on the tongues and then get ready to put the box together. Assembly. It's a good idea at this point to dry-assemble the Creating the Doors BACK (20'/2 x 2&1/2) FRONT (20'/2 x 2&V2) front and back panels fit flush with faces of sides, top, and bottom NOTE: all parts are 3A" plywood bottom NOTE: doors will be cut from case, see box below BOTTOM parts first to figure out the best way to put the case together. Once the parts were glued up, I clamped it all together and made sure the case was square. And, finally, when the glue is dry, you're ready to turn the case into a hardware organizer with doors. The box below walks you through the process. A Split the Case. First, cut through the case along each side (detail 'a'). Then, lower the blade and cut the top and bottom, leaving a little waste to prevent the saw kerfs from closing up and pinching the blade (detail 'b'). Cut through the remaining waste with a utility knife. through sides case doors lower blade, then cut top and bottom leaving thin web of waste door fence distance stays the same for all four cuts ▲ Making the Doors. After adjusting the rip fence to cut two equal doors, lay the door opening down on your table saw. Raise the blade to cut halfway through the ends. Then, flip it over and cut down the middle. FIRST: with opening down make cut halfway through ends SECOND: turn doors over and ends 29 |
