of 24
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3 50
O T E S F R O M T S H O PO 5
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WOODSM'TH
l osn . 'ON R'''~'ntlyone o ( our eom
petnors uh .... hu, , uf
n O O d
magaz ine)
inlruri . . .. . .. 1 a 11('
l 'u l~ ' lion (orwoodYi1lrk
ers. Ir.
CIllk,II~\
I
k
uIII(N.t ,ri.:illg
roj
( ( t.~.
u.uulJ),. I w ulol I'laud any ne w pub
lication bt'l 3U ,llhlnk it .
impor ta nt t o
have
II>
much cho il 'I ' ~ va ri e ty possib le . T he
t I n d
(.mili:.r?
\\'cU, it',
at...
tlw
fonnlll th... ,'lhe prob
I.m . If you .... ,,1 mait ing piece
that
delillecllhi.'I
ne w
publication.
do yo u th in k
it u 1 I 1 , 1 ~:tu .of .. o n ?
\\ 'e are
CUlT rl . . . . . E , , ~ o n e
ba.,
the
l ight lb
. hat
heIAik'
buyu\ l i e
publico:x,n Th ) ......n\ -un. ,, ther it
a : -
at:1ua11\,
{IJI' \ . . m or nut~or if
\\i wI...,
tl,~
ll~J llli.Jlillg
it,
Al.n~ 't.
Oirf lt1Ol
Te d
Kra' icek
_E.
nlrl>t
from the
bel.'IlUI1II~.
d ep t nd ed
j(f't dl
de al on
the
JOI~r')' ~\nd ,,'hat seem s m w-l
curiou......
L..,;
the J01net) ..
e ch < >oe
(or
eaeh
proje ' is
',OIIll
(a I 'yen
m rt l ,;e
and
tenon).
, , 1 U I e
lh e M ; ,,,,u,,' C an
u .
a m odem
v e rs io n ( J;; ur ul 'a n , nn t or b ol ts ).
1'h.u ' o fk no c k . .I n hardware
is gain.
Inl( 8:'1113n('('.It not
s om u ch
a re
f iect ion
our
,u l ,r mobi h S ( J ('i ct y
that
requires
portable furnnu ...
II.
il i ,tand time
S3\'lng
nulJlufu('t'lnllg
procedure,
Much
f
Ih ,. h arw llre com e~ from
~;ur , , -
art,c ularly l\'e ,'1 G erm a ny.
\\ 't ' \ 'l i :M 4.'nl lt tnJ, t
tn ln-
int~n> 't-tt-'(Iln
it.
a nd .. ne e .\ ;1&1>'1It) In the l .S. L'
g~t tmg
f:K,tt~r.,,~
,11
p. . .
>bahly
inclwjp it in m n ....
prujects
IIIh e
fulu,,'
The other Ie o( the coin ' th e old
f as hlo ne rl v .a )
t(.
r n . a . I u -
Jmodc: -dO\\ '1 \ jo in . . ..
- a k~yed m ortIS e and ...nun.
\\ith all
du e
I 1 . r n
to the , ,> < e d n< eflkle r of U5in~
ffilKJE'rn knock-()u n ('C)nnecto~. f 'ould
,lh r tak. Ihl' tim.'
lA l 11....,
a chi se l
an d
hand
tool.
to m akl' m orti..,
and tenon
joint..-;,
It'~~
n t m ( J~
(un,
PRI('E
INC'IIF.ASE.
For
the pa,t'lf,
i.
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N ow Lheclamp
tan
b e c us to m iz ed to y ou r
b e nc h. Mea sw1
II
dog h ) le lo rletermine th e
diameter
o r 3
dowel t ha t will fit do wn in to
th e h ole s. ( A > I . - d i a . d ow el is th e la rg est th e
W o o d s m itJ ,
benc ll w i ll QIWpt.) T hen cut the
do wel 5 long.
1b detennine the 1 0 0 0 0 l io n of the dowel
T he c la mp s an en s)' to m ak e, but they
00\ to be
mad.
in
a
mirrored
set,
and
custom made (o r your .pt Cift < J e k e l at the corner w ith o ne h OlM I
l ld d r aw
a ro un d it
with
t he o th er .
Note: T he m ea su re me nt sta mp ed
On
th e
o uts id e oC th e s o ck et r efe rs 1 0 th e b oll o r n u
it w i l l _ _ p t. n ot th e r d ilL do ff . (A
quarter = about r ad iu s, a n ic ke l abou
1/ 1 ',
radius, a penny
about ''i
radius. and
dime about I , radius.]
Rod'I('YC. lIa (IJ~lIt
Blmd oon. NSW luslmllo
h ole o n Ih e to p plate, m _'U I'C the d istan te
f rom th e f ro nt e di t o f y ou r w o rk be nc h 1 0 th
n e ar ed jl e o f a n~' c lo g h ol e. T h en t ra n sf er t his
d im c no ;io n 1 0 th ~ L O p p la te , The distance
f rom th e n otc h
to
th e n ear edg e of the dow e
,hould e q u a l t h is d imens ion . O n c e this is laid
out, drill hole for the dow el and glue it i
plaee,
~' ina l ly . 1 j lued a thin oor k f ac in g in tb e
Mtclt
to prot.ect th e w ork piece. T hen m ake
t he s ec on d edge c lamp mirror opposite o
the t il> ;l .
2 o a c
E Q U A L
T O - DIStANCE
IflWUN
RtONT l l>G< edges of the front ruiJ,;
C C l se e E n d View in ~ Jg.12.
AS.'
of
h ol es is drilled in the s ide (mmt 'l l.
I.M OUTHOLeS.To layout tht>seholes.
first draw lines on the ends ofthe sh lfraiJ,;
centered on the
hol.s
for th...
connector
bolts, see Fig. 14.Then I~ylh(.helf
o n I h
ide frame so
the
shelf railsare centered on
t he s til es
of the
side
frame. Now extent
the eentert lnes (Into the face of the side
frame $liles, Fij(. 11.
After the eenterlines (Iremarked, also
mark cross
lines I'
from the bouom,
V
from
the lop, and 13' ,. from the top. see
~ig.14.Then I used Portulign to drill '/.
dia. holes through the
. 1 . 1 1 0
s.
AS U:MBI.Y.To tLssemble the shelves to
the side frames, slide a connector
bolt
through the hole in the side Ji-u= and
screw Into the eros.' dowel in the shelf
rail.
Cross Section in Fil(. 15.
lr
the
holes don't match up elUlrtiy, enlarge
lh.
hole in th~ rail. )
ADJUSTA&I.fSHElF
NOn, AU .
SIAn
A ..R U -
OWItONAU.
routtEDG6
AGlJU
11
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WOODS~{lTH
TH E HANDLES
At this point th e basic
cart
is assembled an d
coukI be
used
as is. But I added some
handles on the top edges of
the
s id e f rames
to
m a k e
it
easier
to
m o v e a r ou n d .
CUTSTOCK.
T o make the handles F) rip
two pieces of
4 4
stock 1
W '
wide by 21
long. se e Fig. 16. IVh i le I was at it, also
made another handle (G) 26 long for the
drop
down
door.
Also,
cut one
extra
piece
as
a test piece-
ROUT PROFILE.
Now
use
the
test pieee
to determine the position of the finger
groove on the handle. ut this groove on
the router table using
a * -diameter
core
box bit.
see
Step
in Fig. 17. Adjust the
fence on the router table so when the bit is
at
a height of
y.'
the groove is right on the
outside surface of the side frame (or door
frame), 'fer to Figs. 16and 19.
After determining the position of the
groove, cut it on all of the handles. Then
switch
to
a ~.
round-over bit to round
the
top corner
of
the handle,
see
Step
2
in
fig.
17.And
finally .
round over the bottom edge
of the finger lip with
a
y., round-over bit.
se e Step 3 in ~'ig. 17.
MOIJNT HANOLES.
After the fingt'r
lip~
are routed.
CU L
the handles F) to final
length to match the width of the side
fra~
Then attach the handles with glue
and three screws, counterboring the holes
and filling them with plugs,
see
Fig. 18.
D RO P D OW N D O O R
As an option. added a drop d o w n door.The
oonstraction ofthis door isvirtually identical
to
that
of
th e
shelves .
RA n. s.
Instead
of front and
back rail.
however. the door has a handle (which
ha s
alreadybeen outland a narrowbottomrail,
see Pig.
19.
Cut the bottom rail
I)
to a
width of
Y ,.
an d to a rough lenb
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OODSMlTH
TRill SLATS.
After cutting the handle
' - : : r f
1 IClUIf2A
Z.
nd rail to length, dry-assemble the door
'-f
1tOISf . ._.
1 0 0 . .
using pennies as spacers between the :;l.~tI;,
_ON
see Fig. 19.Now trim the ouutide two slats
40
rop(l)(;
to mateh the length ofthe handle and rail.
J>
Of....,..
~,..c:0
_C>
(11
ASSEMBLY.As on the shelves, round
~v
over the edges ofthe slats. Then gu ahead
and assemble the door.
~
~~/j
PLASTIC LAMINATE INSERT
.......... . an
lAIIItT
DEPnllO
Since the inside faee Qfthedoor
is
thesurCace
?
S
D E T A I l
llt CICI'US
~ ~d~~
fO
O~
that will be used as a work 1 U r a e e . (refer to
A
MOUHlH INGE
photo on page 4), I decided to add plastic
. so ICH tJQQ1IS
SNUG
to o
laminate (Fonnica) to t JW; face.
l I.~
~
OfSHEI l
ROUT
RECESS.
T O
instal l
the laminate, I
routed a recess on the inside 'aceof the
door. Use a router with an edge guide
to
RGUE 6
\\.
rout a border around the inside face of the
I I O O H
=~
oor. see Fig. 20. Adjust the guide to the
thickness of the handle and the rail so the
'
~
bit cuts the recess right on the shoulder
ooot
.: .
line (where the slats meet the handle and
the
rail.
see Cross Section
in
Fig. 20.)
~~
roo....
ooot
H E I G H T
Next, remove the edge guide and rout
MWIJt(
_rooOF
out the center section to form a recess for
ClOSS
S>lWlO
the plastic laminate. see Fig. 21.
S E C D O N
IOTlOMOf
[NSTALL LAMINATE. Cut the plastic
~I
(SlDE'lW)
HI N
IIAUM1WI
hinge. The trick is tomount the hinge so the
_ 2 .
nuckle is dow
not
inIe way when the
CROSS
DOClt
door
is
lowered. see Fig. 24
. . . .
S,
RABBET FOR HINCES. The first step L
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\V OODSM1TH
23 .~
T
WIOJ'KOf-SMa. EQUAlS
THtcKNfSS STroOtll
r :S lO
80
f IGURE I
K YS
Now push tho tenons
thr ou gh th e
m ll rt; s ~ j l lh.:.
\ Jlfl
pj~~: >nd ttlt
t.:lllCn-t1
keys (Cllo fil the key mortises. After the
keys
fit tightly in
the mortises, cut the
key. a ong. see Fig. 7.
R h . , . N a te :
~ inct'
hen. '
rna
be
iJ\e'llL.u~
teneies ro one angted mortise tu unother,
1cut each individua kev to match each kev
mortise and then Inbele.t them. .
Tt :NONS
Next. cut
' ..
long tenon cen-
tered on the ends of ~, h -treteher
t..
match the mortise, see F ij 1. ~ .
KEYMOIl1'ISF .$ .Af ' te r the tenons ar e cut.
chisel an angled key mortise through
each
u 'n () n ,'
explained on p:~ 14and 15. Be
sure lo lay but the cUlt;.
so v t mort i se
angles from
th e
front.and the other mortise
a ng le s [r om lb b ac k. s e t> .F ig . ) \.
1 0
T his eO U ntlj' b en ch u ff~ 1> 'an
inten Sl.ing
c hal l.n ge -
it ,
3 . mb l e d il bo u t Mi l < ,
< 'FeW'>, dowe ls ,
o r
\K.' . YOum i g ht CXIJe;IMeh
c r. (I n m y e ss e. v .
~~dge.glue the piece..
lI clween
side
boards to create a window in th e c en te r
th at's the l en gth ()f th e
mortise (1I l ).
No,, ' ,
c U L
one of
the .ide b o ards
So
th e
distanee
f rom th e
window to the t,lge
of
the
s ide boa r d e qu a ls
th e
di .-um < f f rom
th p
m o r ti s e
to
th e edge of th e en d
h,Ulk .
(Thu.
d is ta n ce \ \ a s5
t1 l/ . .. .
in mv case.)
Next, glue a
f ence on the
uutsid ... o d g c to
hook over th e e dg e of th e b lank . To u sc th e
jig, damp it
ill
place on
th e
end blank and
t OUl
he
mortise> with
a
chisel,
see
Fig.
a .
Then
turn
th e b lank over , book the fence
over the same edge. and set out the match
in g m o rtis e o n th e
other face.
AiWr
sel lin ,
out
the
m om ,
work
f rom both faces to cut them all the w ay
through
th e b la nk .
ST RETC HE RS
Once
al l
of
th e
n lo ltL
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_'0
1--_I I(TO[l--l~
/
'-
NO ........
flGUlft
,.-,~,.
. .
. ,, ooAllOiS
y...
O f
J...
. . . . . ,
t
-.
. ,
0
j
JHtCI( *U Of SfAJ
i
fl1iCXN \S Of SHIU
~
>
,
. . . .
0
.
NO~aH1t.s_
O AlI OtS O N W 't OT M
Of (NO I & . A H J l
AGUila
. 0
KIY
C
4
0 ~ \.
lDCi(GWf_
4 ~ - - - r / - j - i
o
SEA l
\V()()OSMITIi
SlAT AND SHELF
0_ the ' )> helflF.).'l.art bYf,I~j.
I lK>,'aland .hdf
from
4 stock to
a IWcl>
ftongthof21' 'and I OUhldths of II ( ....41)
an d
(,htlf).
(UTTOSll.;. Aft~1'IIHhlanl;,; ..., planed
fl r Mnd,.1 R al. c ut th l .. -at Ifr ....
1 de
and th,
~ht>1(6' ,. ,. Fig.
t; .
To d (,'m.in, t he I l g th of the seat 8 1 1 < 1
.h~I( .
measun-
Ih,'
.houl wl (
fi t
11110s t'1 > pM d ad .. ro uk -< i o n
Ow
i n . < i t I ,
f.....
,.(II '. 'I '.II' ...
orthitlO
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W OOOSMITH
I 1 A I I I
~ 8 I D I
E
ut t ...
lI:
:J It . .
TWO
tIOAIDS)
CUTTING DIAGRAM
Ov t t O U O i :m e ns i o na: 27~ II;It lY d 23
P
h
A n c k
2
11 .
12
2 3 :
I S~cht
2) VI... 2 4 27Yt
1 < . - , . ( .. ) v. .. .
:
o S e c t , ... . . . l~X 24
E5K (I)-
V o
614
E~I 1tom th
p~
o f 4/4__
- E~I Itom ..-
of
414tock.
MATfRlALS LIST
II
I
RGU iE IS
_
-
-
.W
_
~
_ -
_ f
_lUfI NCI
1 C t < G < J E CIJIIWIn
EQUAlSv~ ~~
1------H--jI-..l. IR TSOADO
R G U a . E 1 4
1 .7 1
-.7
~
.9'
AGUI '2
12
CUT (NO PIKS
Afte r the s topped
dadoes
were rou ted .
I
cu t
on e end
pi c
sc e (A I to fina l M a J
an d
then
used that
piece I II I l lY
o ut th e o th er en d.
PRonLf;. 1 0 l ay ou t the arch profile on
the top.
strike a ~. radius are
with the
compass poant
01 1
the
eenterline
19 upfrom
th e bottom end.
This will
make the end
pi_(A)
2 3
l on tr. l ee F ig . 1 1 .
Theil
set the point of t he comp ass o n th e
right edge of the blank3~ up from th e
stopped dado. see Fig. II. Open up the
com pa ss until the pencil end m eets the 4
are
already
drawn and strike another arc,
Rep ea t o n til e J e ft e dg e.
10 form the feet. strike a 4' radius art
with
the
co mpa ss po in t o n th e cen terl in e
right
at
th e b ottom e dg e.
seeFig. ll.
1f.ANDLf;. AJWr th e to p and bottom pro
filesare cut. cut out
tb e h an dl e s lo t.
10
do
this. start by dnl li ng two ..e nd h ol es . s ee
Fig.
12 .Then
cu t the
SIOl
w ith u sa bre sa w
a nd fi le
it
smooth.
see
Fig .
13.
TONGUES ON SEATAND SHElf
After th e h an dl e slo ts w er e c ut, Twent
back
to working on
the
Il eat and shelf. 1 0 lock
these pieces in to th e end p ieces ,
J cut
rab
be tson each end t o p ro du ce t ongu es
that
will
Iiiinto
t he s topped dadoe s.
ssr
THE SA:
Begin by setting the rip
fence as a stop so the
outsi
e dg e o f til e
blade is Vi from the f en ce . s ee Fig. 14.1'hi
will
create a
1l ong tongue .
(The
dadoes
w ere ro ute d ..
0
deep.
This
insures
that
th e
shoulder of the tongu e w iU s ea t firm ly
a ga inst the inside
r a c e
of the end piece
without bottom ing out: see Fig. 1 5.)
N ow ra ise th e b la de h ig h en oo gh to p ro
duce a tongue to lit the dado, see Fig. 14.
(Shop No te : J sneaked up on th is he igh t on 8
lest
sc rap of
the
same thi ckne . .
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1
OODSMITH
C lean 01
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W OO[)SM ITH
4
11
N,'.rl, lay tI,,1,hr
ke y
mllrli~. Thr
j ro,, Iy. V c I. til[,.. ,1 o[lite
II
der
fill ( tt. S I . liu i .S
art
i'. UJXlrl (Iud Ct
1( 'n'tJ (,,, tl'l uo i,U h o(I),t tNlon,
10
Ajlt.,xrn/JtllU
tltt 1 1 1 1 t '
u,ill,,, ('II,~,I,
lay
Ollt nil 111I1(( rt III
1,lIt
'I t b t t C ' k
from III, ,,-,il.d /i ..
TI .Y,I / I I . .
II
Itltdt 1Y1llli Ill
{J fllt tI,II~, Iltt
( H , I
N,d,.
...... SII.
_r fUNf
101lfI OSITf
(1__
.... s AMn
f 6
WlDTMOf nNON
9
Si'l)
ll f, lkl
llrroll lh tAt: mJ$td
plur unltl
lit houldrn
a,... I
gol
R//OlrlJfl
tll~bJck tndr. TIfi R
gnw,.JLI ....
llml'
It'll JllUh. ;I~krf nl.uk.
8
t ' a
dUI( II 1'''
ITu f , . . . .y I r nd. , . -. kfI
by
t . / r . ~
'IC b/wk 1 \ r i< 01 an m'lll~10
1 M ' , , , ,
TMI< ~Jrl ..ta rdtghl
< 'lm[a
arou,.,d IIJ , > t d flirt
kno.
'o..~lliOrtril Je cc
a~
stop o olltsid,
of
hl,ulr
,,II nil(lllt ti
,,-tIl, NIQllldff 1,'1'
T/II I IIInk,
rrytMlrti 1 or, r
II.. blad,
IIll/ill lld t~fIn (.rl .. ,.I.ils } 11( I.
6
y fit tll lg tn t I, d
tIl
thl
If ~t IJ f Cf
1 / 0
I)
tI ,rl,>t'
Th .1,1.h ,l/t/ ' l in . l]
;{Slt/l(lli lht.
miNI
Illf /( 'ld ,Jllfli ltll'I ,,,1
(,,1Q 1iI1/~lll 'I'
5
$t lablc
m,
b/fUI, Jrnt]/u
Q
lilt}.
i ~
Own Jq.lk o f llunJJer I ,. alJd rul
Itdrit ol rJId of (,:sf
pll.... TArnJllp
,* -
TN
and
holrk CJ lA 'T fflgr
4
LAI/
oal ..
' ldlll t ,f lnwn ..., oIrrlrhn-
/0
m4kAlIIII)rt u . t g 1 Q[/nIQJt tqNdU
1M t . / r . rt . ' l II
(mortised) piece and the lenjtlh
of the
.ask (The
'u,k
ISt l ,,11.. f thl It n
t.hat
c om e s o ut the olher
61d , ' )
n.e l l1 >k .h ou ld > lK 'k ooll nll { nol,l~ht( l
aIIo room (or the muller
kc)
mort...,.
pi to ' 1 ' ,
br I,mdtht>
k ry mc or u.. .
,..(er
1 0Step 1 9 (n.e more lcng th l x , . . . .1t ll k, 'y
m oru ,.lhc.~rt~j n t )
For the R\ ' II , ,'r
an
then laid by mark in~ lW(. 1' l i~ ll
lines, lea\ ing a t( n~tn IJ inl l t~. 1 ( ( n
the lines, 1 ( Step I.
Cl1T T~NON SlIouun:R,;
A l \ rr th,
1(
non
,\:8... laid
out,
1
cut
lh(~
Wl10n
~hl)ul(l(~l
on the ,h Ie ' ' . l, dn l lul l .
,. . l s(If ,)a., t~n .lt~
a
nluJ;:h
~ur(ru.~on lht si,le:-of tht l( Jl(ln,
1 ' \ )
,-It'jln
up
thi.
surface. anti It t IKrf , . . .t fit. I~I ,
o f f th e rid ,,,,, with a ch i .. ..l . .,.
S t . 1\ ,
CHAMFER ENDS:, Thln--: ti (Uk
m,)nlhlflJ.[
to t1uon th e ~nd or th, woon . C h i ., ,< , I' '' Il I 11
chamf.... around lhl' ~nd lo hdl' ,ntidl it
in to the morli;e. S( ~SII
II.
I' fh ls hl I,,, ,
p r event chipout a . Ihc I, non comtsO ll t th o
lr~ck.id e of thr mnrtilll .1
Sfitl CHU
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18
To p,. IJCl l t rJl lpPl l1Y. hold
ajilt
aIm.
a gll a)ldfil~a 1 / ,. ('hw,,''er all)l( ltd
Ih~t(/gegoJllt~
mailllll, 1i.,r.JIIlltc.(cI(,{'
Mil,
(mig (/)o.,1jil, lilt k.y
l)(arliSt )
. ,
- J f Ih e , ,,d . o f II k ey 80 i/
(-cutmd
0 , , 1 , , (
tenon.
15
1b lall uu t
I
{;t
(JtI,JlJt(tr Altil
CHrsa
12
8 (I rr 'l lt X '( Is f ,' o u l
(J(t/lt C~tltf TtJJ'tllt'
k.y
mmn. mill, a
hrod point IIr
Ffirsf 'rler bit.
7 ,nl ritoll
(I l th e ~Il(frlibf
1(- i tJ,(I r l li :: rl n .. ;
~/'''~II1 1 , \ 1 1 / 1 J.
KEY MORTISE
The keyed mortise
an d
,n o n j oin t hnl
,.TI('
-K . c , ) d i f f e r e n c e
ever
a
n~lar murti..~,
1 1 ( 1
( .eOOIL
S i 1 K e n ', g lu~ . used , th,' key Cur
wedge p i n ) ~ m (_ . l ( 'h - . tn i t'9 1 n t l' . . n . I ) r pre
ven tin g th e ten on from pu llU lg o ut of
t o o
mortise.
I.AYOUT.To
a cc ura te ly la y
ou t
t O O
loca-
tion of th( key morti .. . fir..'l < lip th e
tenon into th e
mortise and scribe chisel
line on on e s ide o f' th e tr-non, seeStep 9.
N ex
t, layout
an
undoreut
line. se e
Step 10. Th is under cu t
line
,,;11actually be
back
,Ihin t o o
m ortise, Its purpose L
of the jt,in t
tightly
together \lithoul ooltomingouL.
N ow th e r es t o fLh e
lu:y
mo~can be
laid
out. Fin -t. layout th e fron t of
lh. k y
mortise
'I.-
from th e un den :u t line,
se e
Step
11 .
Then lay out
tbe side
lines.
>' 0
th e
distance b etw e en th e sid e lin es
equals
th e
thi
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WOODSMITH
6
tlmNG DI GR M
If yo u asked a group of woodwo rk er s t o
Iisl
loo topthreepowertools, I'll beta drill press
would
ap pe ar s om ew he re o n
almost
every
list. (It's third on mine - right beh lnd t he
table saw
an d
rooter table.)
The
doill
press earned
its
p ositio n in my
shop because
it
does a lo t more than bore
straight holes.
My drill press is a O
a mor ti sing mach ine.
With drum
sanders,
its used
to
smooth
c ur ve d e dg es . A n d, i t' s e ven a turning
tool
when [
want to m a ke a sm all k no b o r re du ce
th e d iamet er o f a s ho rt d owel w ith ou t h av in g
to
set up
th e la the.
I use il with so many differenl accessories,
it s
hard
to nam e them aU without sort ing
through
them, And
that s where
tb e
prob
lem
begins-
Not e ve n
counting
t he v ar io u s
sets
o f b orin g b its , J have 80mue h stu ff f or
m y dnll press that it 's in smal l b ox es seat
tered allover th e sh op . T ha t's w hat m ad e me
decide
the
driU
press deserved a storage
c ab in et o f i ts own .
When p lann ing t he
cabinet.
I built
it
to be
al a height to put th e d riU p re ss table at a
comfortable work ing h e ig h t. T he c ab in et
shown
h er e l~ d es ig ne d
ror th e
small d riU
p re sse s so ld b y Sears and Delta. Youmay
want
to alter th e h ei gh t o f t he c ab in et if yo u
have a larger bench-model drill press like
De lt a's 1 4
ben ch model).
CUTOUT MIlTS
I sta rted b y la yin g OUl th e p arts o n a sin gle
s be et o r p lywood , s ee t he CUl li ng Diagram,
T he n I p la nn ed th e cu tt ing sequence.
PLYW OODPARTS.Begin by first cutling
th e
sheet in half
len gthw ise, th en in to
m an ag eable p iec es, T b do this ...rely on
8
table saw L ak es tw o p eople.
Sin( (l
J was
wo rk ing a lo n e, I u sed
II
po rta bl e c ir cu la r
saw w ith the plyw ood propped up on 2x 4s
on the O oor.T hen cutall the m aU pieces.
Oveto tl
Oimem.JoM: 34~
h .1 411 .lO V . d
A
S l d < r o
2
197/11.30
a
T/60.h... 2
v .
x
974
14
CAdj._I
a r lit17~-22~
P O W O O O
OOlIAfOI .....
0_ 812) Y 4 3
.... X96
A I 1 O W S 4 O C S
IDl lIIGH)
E _
S l d < r o
(2)
.4.19
t
h
NOT,/MJU
f
Ooon 2 v lOY, -
21
LENGTHWlsr
CUT 1S T
G o.w. laic(2) v
% 2
H o.w.S_(2)
v...SYt,.19
AlSONfEO :
0Hf1lOAJO
(f)
o.w.801 II
V 2
V..X7V.48
J Cob_11
Y
x 234 281.
ONrlO lO
K Come
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1
FIGUR
tsi)E
C R O S S S E C T lO N
I ,
I-
~~ = Il
L...v .
lOP
V I E W ) , -
~ ~ t t
IV
CIOSSIWCf
J . . . . . . . .
I
__j_
,t ..
e D G e ~
t
TlIIM ./
. c .
~ ~
_-:-- [- V .
i::--
I
1 : . .
NAIl -
e
~ ~ ~
:
S I D E
emlWO EaS)
> ;
.
t
I
CASE JO INERY
l\ercul1ing
a ll
the plywoodpieces to size.
the rabbet joints for the casecan be made.
RABBETSWES.
The
fitsl
S t of rabheLllis
on the top and bottom ends of both side
pieces (A), to join the si de s to the
t .op
an d
bottom (B), se e D eta il A , Fig. I.
BACK RABBETS.
The second set of rab-
bets is cut onthe inside rear edge ofall four
c as e pieces A and 8). T h h ; r a bb e t is v . by
i
to hold the back, se e DeLa iI B , Fig. I .
A SS EM l IlE C AS E
' T ' h e next step isjoining the case parts. lbdo
this, Ise d glue
an d
some f8Slenets rarely
E'enin
lVood m ilh
nails,
NAlts AS
CLA.'lfPS. [
generally object to
nails,
but tbey have their placeon plywood
projects. They're handier than clamps for
pulling joints tight and holding parts to
gether while the glue isdrying.
PRgnR~ The trick to using nail. for
pulling joints tight
is to
predrive them
before the pieces are positioned for assem
bly.That is, the nails are driven at an angle
with the points poking out about V , . . Then
glue is spread on the joints and the pieces
are aligned. see Fig. 2.
A~he pieces are pressed together, the
points bite into the wood. Because the nails
are angled, they draw the joinllogether.
BACK.
After the glue is dry on lhe four
corners of the cabinet, the back can be cut
from \4 Ma..lnite:;0 it fits into the back
rabbet,
se e
F'ig. 3.
(l
usually cut the back lo
exact size to fit in the rabbets so it squares
the
case .
Buton
this
cabinet [cut the
back
about V s m a J l in both dimensions in order
to use a trick to align the doors.)
Tomount the back. drill Y ,. shank boles
spaced 6 apart for No.6 X screws, Then
place the back in the rabbets so there's
a b o u t a space a r o u n d all ed ges , Now
drill a pilot hole r one screw in the center
of each
e d g e
and screw in the four screws
to
give
the
case
some
rigidity.
Shop Note: Don ' t app ly glue or use
m o r e
than four screws at this point . Shiflingthe
C
as e
in relation to
th e
back is the key to
getling the doors square la te r.
CROSSBRACE.With the back holding
the ease square, a cross brace CL)can
be
added to divide the section r the drawer
and the doors, see Fig. 4. Cut the brace to
length to
fit
between the sides. (Take this
measurement at the top in
ease
the ply.
wood sides are buckled or bowed.)
BRACEPOSmON. The brace is
6 1.
[rom
the top of the cabinet. Also. it's set back ' I i I
[rom the front
e d g e
of the sides. (After the
thick trim strips are added.
the
brace
will be 0/. from the front to allow r the
'Y,thickdoors. see Fig. S.)
'TRIM STRIPS-
T he last step is to rip
0/. . -. . ::: f = i ~ f
. J ~ : r 7 t , : ~ : : i te r ~ ~ g ~ ~ e d
on the ~ 7 \
V _)
~w~OO~o~sM~rn~~~~ ~======~~~~~~~
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WOOOSMITH
DOORS
A fter h e
ba:;lc
case ~,complete , CUta r ei n
forcing plate
(N)
from
s to ck to
fit
snugly
between
th e sides, see Fig. 7.
(This adds
suppon (J
th e
LOpd(J esn't sag.)
N ow the d ec rs e an b e made. Todetennine
the w id th of the door
panel
to ta l u p
all
o r
th e
parts and spaces
that
fit
betw een the
5ides.
This
i nc lu d es t he two h in ge s. f ou r
I.
thick
b im s bip :< . and a
I f .
gap
b etwe en the
doon
. . ,
LH.
DOOR
HoI
-rr-~j----
ROUtE 9
I ....
;
LF
~ t-t--r----2r
i
..- _-~
. _ r - - . - . . - - , - - . .
: i~
-~ , 1_.. i RSN~ PlAn ~
. . . _ _ V ~ - i L ~ ~ : = I - . - , - = - - = - ~ t , - - - - - , - . , - . - - - i - 1
I
: 1
AGUUI
FIGUlt7
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BACK@
,
:
0 IU 1 HO lE S ' BOTtOM
Of C aiNtftNUNEwmf
H O t S
COflHI l
I..OQ(S
J :
RGUIf
~
R .H .INNER
DAAWER~
0'
JO INT
D E T A lt -riff S O ?
~
f l OHT ~
14
~l
I '~' -
':fa
,
fIG URE
- -
.,'
1--__
- 1 12-
--t
.
i
. , , -
- i
_,1
WOOOSMITH
SIDES.Now the drawer sides (Hl ca n -
cut LO size.
Rip
them LO the
s ame
width as
the
front.
and to a
length
o f 1 9
DRAWER JOINERY
The drawers are joined with thtsame l'imple
rabbet join used on the ca.~.
I'RONTIIlACK RABBETS.
The rabbets on
the front and back are
I.
bS
lI. .
see Fill.
IS.
When gluing the joint. ~ther. us e
the same angled nail triek used Lu pulilhe
joinL.light,
Ie('
Joint
Detail
in }'ig.
13 .
BOTTOM DADO. Aller rabbeting the
ends of the front and back. make a
Y o
by
Y o
groove '. up
from
the
bottom of
the
front and $ide pieces to hold the ~1a.,oniLe
bo tt om , s ee Boue rn D e ta il
in Fig.
13.
C(.&ARANCE. The last step bofore as
sembling the drawers
i~
utting
Y .
from
thp top of
t
he sides and back to allow
clearance for the reinforcement plate
(mounted under the lop). see
Fig.
13.Then
nail and
glue
the drawer tugelh~.
TRIM eecrxc.
\Vhen the glue dries. the
trim can be applied. Begin by putting the
shorter trim pieces that conceal the the
gaps for the drawer slides, see Pig. 14.
Next, trim the nil.of these short pieces
Ou with the top and bottom edges. Then
apply the lopand bottom strips,
SLIDING HAlU)WAR&.
With the
drawer
complete.
lb.
sliding hardware can be
In -
stalled.
Begin by
mounting the inner
draw-
er ),'Ilide;;to the ides of the drawer so the
mounting holes
are
I~
p
from the
draw-
er bottom, see Fig. 14. Then mount the
outer drawer guide to lhe s ide of the
cabinet with its mounting buies aligned
0 /,.
above the cross brace. see Fig. 15.
Shop Note: Tocenter the drawer. use the
vertical screw slots for initial itioning.
Next, adjust lhe bnrdwart' up or down
until the
drawer is centered. Then put
in
the screws througf the round screw hole.s,
BASE
A lW r the cabinet i s . .. ..embled . base is
made. This
base i re;s
C - a b in et H a r d
tu C
Kit ' 18.
& nd
it with yo ur name,
address .
and paymen t
( no c l1 a rg e c ar ds
o r
p h o ne o r de rs , p le a se ) to : Dri l l
I're;.