Woodworker's Journal 2007-Winter, страница 29




Woodworker

Next, rout the 3/4"-wide by 1/4"-deep dado in the center shelf for securing the upper section divider. The same size dadoes must also be routed into the upper section divider for the drawer dividers, as shown in Figure 4. Finish up on this piece by cutting notches out of the upper corners so that it fits around the web frame stiles.

All the shelf dado joints in the side walls are reinforced with screws. To accurately drill the pilot holes for these #8-2" wood screws, first dry-assemble the cabinet, then draw the three lines on the outside face of each side wall to indicate the center of each dado or rabbet. One hole is centered on each stile and two more are spaced on the panel. Drill 3/8"-diameter by 5/16"-deep counterbores for the plugs and follow the counterbores with a 5/32"-diameter bit for drilling the 2"-deep pilot holes.

One operation that you definitely should perform now rather than after the cabinet is assembled is drilling the pilot holes for the Blum drawer slides (pieces 28). Set the Blum slides 13/16" back from the front edge of the right side wall and the upper section divider to allow for the inset drawer fronts, and

position the slides directly above each drawer divider dado. Use an awl to mark the screw locations and then drill the pilot holes with a 1/8"-diameter bit.

Disassemble the cabinet and spread glue in the side wall dadoes for the bottom shelf and the center shelf. Pull these four pieces together once again and drive the 16 screws into place. Now spread more glue in the center shelf dado, the two dadoes in the upper section divider and in the two remaining dadoes in the right side wall. Slip the upper section divider into the center shelf dado, then set the lower drawer divider in place, followed by the upper drawer divider, and slowly pull the assembly together.

Wrap up the carcass assembly by applying glue to the rabbets on the side walls and drop in the web frame, slipping it over the upper section divider. Fasten the walls to the web frame with #8-2" screws, and drill countersunk 5/32" pilot holes through the web frame into the upper section divider. Secure the joints with #8-2" screws. Lastly, glue walnut plugs (pieces 14) into the counterbored holes in the side walls, and sand them flush when the glue dries.

Figure 1: To make this straightedge jig, fasten a straight, narrow board to an oversized piece of hardboard, then rout the edge of the jig with the router and bit you intend to use for the dado. Next, align and clamp the edge of the jig with the layout line and rout the dado.

Figure 2: Use 1/4"-20 threaded inserts and 1"-long bolts to hold the interchangeable insert plates in place.

Figure 3: Position the laminate, then remove the sticks one at a time, rolling the laminate down as you go.

Making Drawers and Doors

The cabinet doors are made from 3/4" plywood (pieces 18) banded on their vertical edges with 3/4" by 1/2" banding (pieces 19) and trimmed on the top and bottom edges with rails (pieces 20). Regularly refer to the Exploded Views of the doors and drawers throughout this section of the project. Cut the plywood pieces to size, then glue on the banding strips. Now cut the rails and join them to the plywood with biscuits.

The drawers are made with a simple, durable joint. Cut the 1/2"-thick plywood drawer sides (pieces 21), fronts (pieces 22) and backs (pieces 23) to the sizes shown in the Material List. Next, install a dado blade in the table saw and set it to cut 1/4"-wide by 1/4"-deep

Winter 2007

29



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