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O TE S FR O M T S H O PO 8
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WOODSM I1'H
AB011l ' TH IS ISSUE, How high shoul d
a
issue.
What
it gets down
to
is th at
the
QheS I of drawers be? That's a good q u e s - height of the ease is actually d ete rm in ed
tion. And one tha t's ac tu ally v ery difficul t by the draw ers, whic h a re mu lt ip le s of /. .
to answer.
But t
wou ld
be too easy
if
that
were
th e
When you set out to build a chest of only co nsi deration,
d ra w e rs ,
there are two m ajor
st e p s :
build - In a dd ition
to th e
dovetai l lay out, y ou
in g th e c he st itse lf,
an d
then building the have
to
a ll ow f or th e c le ara nc e ab ov e e ac h
d raw ers to
fit, So
it would seem easy
to
drawer.
MOl'
pla n nin g a he ad. A ls o, s in c e
say,
W eU , I 'd lik e to b uild a c hes t 30 bigh we
wanted to
us e
plastic
glid e
strips (to
with four drawers. h elp th e d raw er s lid e in
aO O
o ut e as ily), w e
But th e design of any woodworking pro- had
to
a llo w fo r the th ic kn ess o f th e strip s
je et is
a
comb in a ti on o f art a nd s cie nc e.
Th e
in d ete rm in in g th e height
of
each opening.
rt
is the aes thetics of the design. The There's one last d etail: the th ick ness o f
science is figu ring out how
to
make all the the stock. W e list the thic kness of 4 1 4 stock
p ie ce s f it to g eth e l', as y , .
4 /4 s
the designa tion for lum -
Okay, Don, sounds
li ke you re
about
be l th at s 1 t. hic k
when
it s rough 8a \V l1.
to get
into
a
treatise on design.
Let s
skip
Then
it's plan ed down to final thicknes.
s,
a ll th at and gel down to the lutty gritloy, The N atio nal H ard wo od Lumber ~ ia-
In
a nutshell , I'm alw ays
amaze d
at
th e .tion sets the
standar d
of v . th ick for
amount of bas ic pla nning req uired
to
build most h a rdwood s. )
what I th in k sh ould be
a
sim ple ches t
of
au t in reality , th e sto ck you use may be
drawers. t
seems
like
a never-endingser- a
differen t cti ql th ickness - usually it's
ies of det ail s
an d
decisions, so me wh ere b etw ee n
y., and Y I , r ,
You
About a
year
ag o, we were building the have
to
t ak e th is
into
a ccoun t when ad ding
s ev en -d raw er lin ge lie dresser fO l' issu e in the thickness of th e rails that ar e
be
No. 53 . 'V e w anted
to
use dovetails
to join
tw ee n e ac h
drawer,
the drawers,
b u t
sin c e th ere were so m allY , So, detennining
th e
heig h L of
a
dresser
we de ci ded to u se a route r
and
dovetail jig is n ot e asy. T he d im ensio ns w e sh ow in the
rather than cu t th em all by hand, plans m ay seem odd. PO I' e x ample , th e
Just about
that
tim e w e received a tip basic
case
fo r th e
dresser
is
25',),,,,
high ,
(rom W illiam
Schultz, a subscribe r from
an odd dim ension. But it's act ua lly ju st th e
A lbuquerqu e, N ew M ex ico . H e had b uilt
s u m
of
all
these details .
dovetad
jig
aO O
mad e
hi s
own templa te
SOUltCflBOOI\.
you 've been
s ubserib-
usi ng a box joint jig. ing
fOI
awh ile , y ou 'll rem emb er th e
Wood-
D o u g
Hicks
d e c id e d to b u il d
th e jig
to Itmitlr OI,rceboi>k.W e
b eg an p ublishing it
se e how it work ed. fn the m iddl e of that in
1 9 1 ,
(b ut
t
d id n't c om e out last year).
p ro c e s s , Ken s to p p e d by an d mentioned The b a si c id ea b eh in d th e Sm,roobook is
that
he . a l w a y s wan ted
to
build jig th at
to
provide in fo rm ation for w oodw ork ers.
u s e d c am s in ste ad o f w in g nuts
to
hold t he Rather than add advertis ing
to
Wood
work pieces in
p la c e .
Then Ted made a few
smith,
we decided
to
pu blish the
Source
comments
an d
ch anges . Soon we-had
a new brxik.
It's a listin g o f c om pa nie s who have
a p p ro a c h to a
dovetail jig . mail-order
catalogs,
or
offer
info rm ation
0)1
Unfortunately . we didn't ha ve enough tools and supplies for
woodwersers.
room in
that
is sue to show the jig . So we Thi~ year s So rce lXJQk, will be m ailed
waite d until we began bua( lin g the com- free
to
a ll a ct iv e
WoodS1ni lh
subsc rib ers
panion
piece (the cherry
d re s s e r
ShOWI lin
lIS of
Sep tember
(988). Pe l
like
to
invito
th is iss ue)
to
sh ow the dovet ai l jig . you
1 .0
u se th e
Solt1 'cebook
if you're look-
S ince we had the doveta il jig , we wanted ing for catalogs
01
o th er in fo rmation, It's
1 .0
build the drawers fO I'th e
dresser
with an easy way to order
a
lo t of
information,
it , This automatically
sets
so m e
parame- PltOTEcrrvS COVER.
For quite a few
ters
fOI
the
~ize
of the draw ers.
years
w e'v e a dd ed
a
protective
COvel
to
W hen you use a dovetail jig , the pins
IVood.~mit1.
U was a convenient way
to
an d
so cket s
ar e
cut w ith a
template
th at's show the covers of
back
issues.
b a s e d on inc re me nts o f 1 , 0 1 . (This d i m e n - But we gpt to th e point thai there w ere
sion
actually com es
from
th e V .. -< lia. m ore
back
i ss ue s a v ail ab le than th ere w as
guide bushing that's u s e d
to
guide the r o o m
to
show t h e m , W ith this is sue, w e've
route) ..) But the layout of t he dovetails has added an e x p a n d e d version of th e p r o t e c
to
be mu ltip le s o f v ,, because
at tbe tive
cover,
and
we were able to
add
an ex
m inim um
YOII
need one socket
and
two panded order form and some
in form ation
balf-pin s (o ne
On top,
one on the bottom )
about
th e
kits
shown in the past issues.
to
make
a
joint.
NEXT MAILING,
The next issue of
Wood-
I'm getting a li tt le s ide tr acked hers.
sm t
(N o, 59) will be mai led tlw ing the
Back
to
the design of the
dresser
i ll t his
week
o f O c tober
3 1, 19 88 ,
WOODSMITH (ISSN
0164-4114)
is
pob
lis hed bimonlh ly (Februal)l , Apri l,J une, Au
gus t. Octobe r, Dece mber) by W oo dsm ith
Publi sh ing Co ..
2200
Grand Ave ., D es
M oine s, IA
50312.
WOOdsmi th
is a re giS te red lrad em ark
0 1
WoocIsmilhPubl ishing Co.
\tCopyrigh t
1988
b yWoodsmith PubUshing
Co. A llR ights R es erv ed .
S ub scrip tio ns : One year (6 iss ues) $1 2 .95 ,
TwoYear s
(12
issues)
22 .95. Canada
an d
Foreign :
add 2
PIl r ye ar, U .S . fundS only .
S ing le.c op y p rice ,
3 .50.
Second Class Postage Paid at Des
M oihe s, Io wa.
Postmaster: Send change
01
address
notice , to W ood smilh Publishing
c o ., 2200
Grand Ave., D e s M oines , IA 5 0 3 1 2,
BACK ISSUES: A ll back issues of
Woodsmi th
are still availab le. For a fr ee
bookle t desclibinglhe co n te n ts and prices o f
a ll back iss ues , ju st se nd us your n am e an d
ad dres s
1 0
th e addre ss
ab o v e .
SAMPLE COPY : W e willbe h ap py to send a
free sam ple copy of WorxJsrnfth o a ny on e
you th i nkwould enjoy it J us t s end u s his/he r
n a m e and a dd re s s .
wdust
0peratOoos Steve K rohmer
M arketingM anage r S te ve D o zie r
SioreM an agers:
S I. L o u is . M D J on B eh rle
8 e rke i< ly .
CA Mi cha el DeHaven
Des
M oines .IA K en t We ls h
The W oodsmith Sto re
Edit ,
Dona ld B . P es ch ke
Oe$Igij
Direct' Ted Kra li cek
Manag ing
EdrtOf
Douglas
L.
Hicks
A ss istantEd ,I' Doug la s M .U c ls te r
P ro je ct Designer K e n Munk el
Technlcal llustrators Dav id Kreyl ing
Cary Chr is tensen
RodStoakes
Ch ri s G lowack i
Customer
SeMce
S andy B aum , M gr.
J ac ki e S tr oud
PatKoob
L is a Thompson
Computer
0 p e r a1 ) O n s
Ken M i ne r
Admin istrativeAssIS. Cher yl Scot t
JeanC.rey
BuildingM ai ntenance A r ch ie K r au se
Number
58
August ,
1988
rodsmith
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3/24
Now , place th e
ro uter so
th e
w ing is
on
the work
surface and the
bit
hangs
slightly
over the outs ide o f the ed gin~ stri p. M ove
tbe bit slow ly into th e strip kee pi ng one
h an d se cu rely pressed down on the bl ock
'I 'he top layer follow s the ,..
dius
of the
router
on on e end, but
has
a
wing
that
st icks out abo ut
6
beyond the
router
on
th e
other
end.
After
cutting
this
piec e to
size,
T
use d th e plas tic
I(lUW'
bas e as a
tem plate to mark
the location
of
the
bi t
hole
and
SCrew holes. Then
I
glued
a
block
as a
handle to the top of the win g.
Ne xt. c ut a su b base to shape with 9()0
po int and glue it
to
th e
top
la ye r so th at
~
stops
short of
th e
b it. B y
making
tb e
su b
base
come to a 9()0
p oin t, y ou
can
easily
work into Ute COt11er or a workpiece that,
ha s e db ng
on tw o
sides.
1 '0 u se th e
jig,
screw it to the bottom of
t.he router and mount a stl'aight bit, Then
adjust the dep th
S O
th e b it jus t
touches
the
work
su rface.
B lO C K ftAN D LE
3
V O OD
MITH
If
yo u'd lik e to sh are a w oo dw orking tip with othe r
readers of W oodsm ;rh . send your Idea 10:
Woodsmlth. TIp & Tec hn iques. 2 20 0 G ra nd
Ave.. Oes Moines, Iowa 50312.
W e
pay
a m in im um a 51 0 lor UpS, I I I l O S e l y
ap -
plied a little proud of the adjacent
surface,
This
is ot ten
th e
case
,,~ th ta ble tops,
coun
tertops, and
plywood panels.
use my router
with
an
auxiliary base
to
trim off the extra edging. To do this,
start by
re mo vin g th e p la stic base plate
f i O n l
the oute r and mount
a
two-lay er
base m ade from
1 . 0
M as onite .
The
bag
d o e s n t
catch
a U
of the dust
( the,., , s still som e that goes out the back
J the saw1.
but
it's a big im provement
(>\ < '1 . .
h;.t us ed to end up O n my floor.
Mbriey H. Grt/.Ju
Belle il/e, Ontario
GARBAGE SAG
H E lD T O
R rot, ICER W ITH
L A R G E R U f l 8 . E R
~NOOft
B U N Ge E C O ftD
o
Then,
visited a lo ca l b uild in g c en te r
an d fo un d a fu nnel-shaped furnace a ir d uc t
re duce r m ad e from sheet m eta l. There are
a variety of
shapes
an d s iz es , b ut
get
one
with
a flat shoulde r that ru ns
around
th e
bottom .
Now cat an opening in th e plywood pan el
with
a sa bre
sa w
t o s ec ep t
th e
shee t m et
al re duce r. By cu tting carefully , you
, 1
get a
sn ug enough fit SO that the reduce r
c a n ju st be p ushed in lo the opening a nd
held w itho ut f as tener s. (I f neOO$$3' ) ' ,t can
be strew ed in pla ce w ith a couple o f sh eet
meta l
s c re w s f ro m
t he i ns id e .)
~l y
wife
se wed up
a
cloth bag w ith
a
drawstring \0
catch the ch ip s, but a p lastic
garbage
bag and
large rubber
band or
bungee cord would also work.
TABLE SAW DUST BAG
In order to t U~o wn o n s aw du st and chip s
~Io w ing all over m y
sh op , 1
added
a
dust
bag tQ th e bo ttom of my table saw .
ta rtro by cutting
a
piece of 'l(, ply
w o od to bolt W the b ottom of
my
ta ble saw
ca binet .
__ T_i( sTechnigu_e_s __
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W O O DSM ITH
R IP
HNCe
A G U R E 2
1 1
DADO ES
V ~Ollie ON INS IOE _
F CE OF Bo m EN D P NE LS
END DETA il
NO
P NE L
E ND PA NE L
@
,
tt O U I D E R
C OR NE R DE TAJ ,
ED GE GL UE lYIO END
1 f = , , J : : : : : P ~ A N ~ E l S
lOM 41 S TOCK
RGU~E1
,.
.
.
- _
,
_
. ~ ~~
.
.
4
Probably th e m ost in teres tin g p< ut about
building thi s ho pe
chest
is the
corner
joint,
It's a
va ri at ion o f
a
to ngue
a nd g roove ,
but
the co rn ers are beveled an d shou lder s ar e
added to both ends of the bev el. It so unds
co mplicated, but it's actually easy, A nd it
produce s a unique jo int that adds a lo t to
th e overall ap pear ance of th e chest,
END PA NELS
[ began work on th e ches t b y e dg e- glui ng'
en ough
I
stock 0/,. ac tu al t hi ck n es s)
to m ake two end pan el s (A) that were
roughly
18
w id e an d
21
lo ng. After th e
glue dri es, p la ne
0)
belt san(l the pan el s
nat.
Then
cu t
the m to fi n is hed size :
17
wide
by
20
long,
see Fig. 1.
Shop
Note :
rt:.
im portant that these
panels
be
planed 0) sa nded to a iform
th ickn ess acro ss thei r w idth . Ifthey 're not
perfectly uniform, the shoulder cut o n th e
outs ide of the jo int
will loo k wavy.
C UT DADOES. After the e)) d panels are
to si7 .e, y ou can he gi n work on the C O l1 I e r
jo in t .. S tar t by cutt in g ~ w id e dadoes on
th e in sid e fat e of the end panels . (A lt hough
this jo in t is traditionally called a tongue
and glWL e, i t's ac tually a
to ngue
an d dado
si nce the groove runs across the grain.)
To cut th e dad oes, set the rip fe nce so
th e distance fr om the fen ce to th e outside
of the saw blade equal s the th ic kness of
your stock,
minus
1 1 < tq
allow
for th e
shoulde r), s ee Step ~ in F ig . 2Since
J used
l It thick
stock,
I
se t the
fence
lo
fr om th e outs ide of the bl ad e, Then cut a
' l' Id ' deep dado at both ends of the p anels.
R OOT
DADO.
N ex t,
I
used the router
tab le to ro u t a ~ d ee p d ad o o n th e o th er
face of each pan el (t he o utsid e face). 'P his
dado will law form a shoulder alongside
the corner angle, see C orner D etail.
ro rou t this
dad o, mount a o
straight
bi t in th e ro ute r ta ble and se t the fence so
the outside of the bit is in line w ith the
dado you just cut on th e saw , see S > I)2 .
ROUTANGLE AiteJ th e d ad oes a re c ut,
switch
to
a
cham fe r
b i e
to
rout a 4~
angle
along U le
outside
end of the panels, se e
Step
3. T o get uniform V I' shoulders at
both ends of the cham fer, sneak up 0 11 th e
fin al e ut b y raising the
bit
a li ttle at a tim e
un ti l both shou lde rs eq ual 1 1
fRONT AND BACK
N ex t, work
ca ll
begin
011
the n'O nt B)an d
back C) panels. A gai n , these panels ar e
edge g lu ed Irom 44 sto ck, a nd planed to
a uniform thickness.
C UT1 ' 0
SI ZE .
'T he leng th of both panel s
is the sa me (35~ >, but the w idth vari es
____ H_o~e
h st
AN HEIRLOOM FOR THE FUTURE
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5
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FIG UR E 3
\VOODSMITH
si nc e a drawer fits unde r the fro nt pane l
(B).
First,
cu t th e ba ck pane l ( C ) to a width
o f ]7 ,
se e
F ig. 3.
N ext, c u t the fro nt pa ne l (B )
6V il
1 'lSS
in w idth tha n the bac k pa ne l, se e F ig . 8
(T his measu re ment take s into
consider .. -
tion the 5 h d ra we r h eig ht, a
v
g dp
above the dra wer , and a
0/,. filler ship
b elo w the drawe r, re fe r to F ig . 10.)
TO NG U l: .
AftNthe pa ne ls
a re c ut
to
size ,
cu t a ra bbe t o n the end o f ea ch piec e to
create a 'h -I ong to ngue
t o
fit in the
dadoes
o n th e end pa ne ls .
r
cu t th is on th e
ro u te r ta ble , see C orner De ta il i ll F ig . 8 .
Sneak up on the cu t
unti l
the tongu e
fits
snu gl y in to the dado .
RUNNER A N D SH EL F G ROOV ES .There 'S
one mo re s tep o n the fro nt and back
pane ls. Two v. . -w ide g ro ove s have to be
cu t on the inside fa ce s o f these pane ls to
ho ld tray runners and
a
shelf,
se e
Fig . 3.
SHELF
Once th e g ro o ve s ar e cu t, a plywood she lf
0
ca n
b e m ad e,
se e
Fig .
4.
To dete rmine
th e w idth of th e s he lf (f rom f ro n t to back),
dr y-a s s emble the che st and mea su re the
i ns id e d is ta n c e
between
the end pane ls .
T hen add
fl
fo r the tw o V . . < . l e e p dadoes .
T he length o f the she lf is equa l to th e
in sid e w id th o f th e c as e. (T h ere a re n't any
to ng ue s on the ends o f the she lf.)
TO N G U E . N ow ro u t ra bbe ts on the fr ont
a nd b ac k e dg es to fo rm to ngues ,
se e
D etail
in F ig.
4 . A gain, 'sneak up
on this
c u t u ntil
th e to ng ue ju st
fits
th e g ro o ve .
ASSEM BLY
W he n the sh elf
is
comple te , the b as ic c as e
can b e a s sembl ed.
Start
by g lu in g th e f ro n t
(B) and back C pane ls to o ne end pane l
A. To he lp ho ld the assem bly squ are ,
s lide the she lf (D ) into th e grooves from
th e o pen end.
After
the gl u e
dries, glue
the othe r end pane l in pla c e .
RUNNERS AND TOP TRIM
After
the c as e
is
a s s embled, two runners
E
are
added to bo ld
a
stiding tray.
RU N NER S . C u t the
runners
to
a
wid th o f
V I ,
s ee R u nn er
De ta il i ll F i g.
6.
Then cu t
ra bb ets a lo ng e ac h e dg e, fo rm ing a to ngue
c ente red on th e runne rs tha t
fits
th e o
grooves in the front and back
panels,
Afte r th e to ng ue s
are formed,
cu t the
ru nners to lengt h to fi t inside the
case .
Then glu e the ru nne rs into th e g ro ov es.
S h op N o te : I t' s d i ff icu lt to
clamp
th e
run
ne rs .
So
1
wedged
a
le ngth o f sc rap be
tw een the runne rs to P I eS S th em in
place
unti l
the glu e dri ed.
TOP TR IM . The final
step
is to add
W -
thick trim strip
F)
around th e to p edges ,
se e F ig . 5 . C ut th e trim str ip 1V .. wide
and ro und ove r the bo ttom outs ide edge ,
se e T rim D eta il in F ig. 5. T he n, miter th e
pieces
to
length, and glu e and na il them to
the to p o f the
case .
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W OODSMlTH
THE BASE FRAME
O nce th e case w as
complete,
I b e g a n work
on
t he b< I$C .The bas e
consists of
a s cr oll
cut kickboard frame with a
molding
StrIll
glued on lop o f it, ref er to Fig. 8 .
KICKBOARD FRAM . To
make
th e kick
board
fram e , cut the fl'QntJbackpieces
(G),
an d
tw o
S id es (H)
fI 'om
41 4steck
to
a
width
of
4 ,
se e
fig.
6 ,
Then m iter b oth ends
of the front/b ec k p ie ce s so the length of
e a c h piec e (from long p oin t to long p oin t)
is tv. longer
th an
the w idth of the
as-
sembled ease. N ext m iter the side p ieces
so
they're
V i longer than the depth of
the case, (This creates a fram e that is
la,-ger
than
th e
case
on all
four sides.)
KERF
A. NO
SPLINE. 1 0 help keep the
mi te rs a li gned
while
clamping, 1cu t
ker f
in each miter and added a
sp line, see
Comer
Detail in F ig. 6.
SCROLLWORK.Be fo re g lu in g the
frame
to gether, I cut a SCl 'Q1 I esign al ong the
b otto m edges. S tart b y drilling J -4 iam e
te l'
ho le s
near
th e
end of each piece,
J
1/.
up from the bottom edge, s e e Fig. 7 .
Next,
m a ke a
poster board half-pattern
fo llow ing
th e
dimensions
in F ig . 7. (Or
send for the
patterns,
see page 24 .) Then
tra ce th e p attern on the w orkpiece and cu i
it ou t w ith a sabre saw or band saw .
ASSEMBLY, W hen the scrollwork has
been cut and sanded , glue th e kiekboard
frame tcgether.
~fOLDINGS1'RIP. 1 '0 com plete the
base
fram e, 1 m ade a
m old i n g
st rip
(1)
that's
glued
to
th e
top
edg e o f the fram e, see Fig .
8, Sta.t by
c uttin g tw o
p ieces
of
41 4
stock
ror the sides to a rough length o f 2 2 . Then
cut the front
and
back pieces to a rough
le ng th of
38'.
B efo re c utlin g tb e pieces to f ina l leu ,>th ,
I ro u te d a
Roman
a g e e p ro file a lo ng th e
lop edge, see Step 1 in Fig. 8. Then cut a
rabbet alo ng the b ottom edge, see Step 2.
Shop N ote: This rabbet should be I/,/
less in \\;dth than the thickness of your
stock
to create
a a shoulde r l l A t } , in my
ea se ). s ee CI 'OSSSect ion in Fig . 8 .
MITER M OLDING.After th e ra bbets are
cu t, m ite r th e p ie ce s so th e sh ou ld er of the
rab be t fits a ga in st th e in side edges o f the
k ic kb oa rd fra m e , s e e F ig . 8. T he n g lu e the
molding
strips
in p lac e.
ASS EM BL Y .
To attach the case to the
kiekhoard frame, drill
o/i.'
shank
holes
co m pletely th ro ugh th e
base molding,
se e
Fi g . 8. Then tum
th e ea se u psid e d ow n an d
position the base on top of it. Now chill
p ilo t hole s, a nd .screw th e bas e
to
the case ,
see Fig. 9.
FD .LEllS'l'R1P . A fter the base ftam e w as
screw ed to the ease, I ad ded a
ont
fi ller
strip (J) to the bo ttom of the draw... open
ing , see Fig. 9. I t's p o si ti on ed t o create an
\1,;'
shoulder where the ends o f the strip
m eel the end panels (A ). (This co rr espond s
with the
V shoulder on
the
co m e r jO in t. )
6
Q)
FRONT -
FIlL ER STRI P
8
'
WOOOSCRW -
Kl CKBOARD
SIOE-~ '
:- - -
c
CUT1 fiT __
O PE N IN G ' '\
f IGUR E 9
1 1
1 1
: 1 ''''lllI lf
~ml'~'
stRA IGHT
'. IT-
STE P 2
CROSS SECTION
l I l J . o '-'i,
l J I~
r~t:;;:-JJ..
II1 ,, -
; o K
L.. 0/ . ;
F -
O R IU ~ H A N K
U
r-
HOlES
TO
AnACH
BASE TO CASE
STep 1
1 1 0 .
T....
fE N CE
D
/ -MOLDING
ST RIP
f IGURE 8
LA Y OUT
PA rrt RN
Am .
ctnTlNG
T O L E I iG i H
FI GURE
ORlll I ~Ol
8 FO RE tAYlNG
our
PATTEItN
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7
,.,.
1 M
fI GU R E 1 3
.- lOMAN
00 .. 811
UD PANS.
E DG E G lU E U O
RC4 4 S T O c K
r
y o
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F IG U R e 1 2
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B A C K T R IM
y o
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.... HOU
TO.
r-
-
-
S lO E T R IM
(fULL
ATlHN)
.1
.
PlUG
, .
-
SIDE
TRIM
@
S E T
aAQ( j,.
F ltO M _ .
.- O N
A U .
S I D E S
,
-
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20 .-
SIDE
T R I M
o
ROOt 11
GLUE.UIIIN .
TO U P O N
1NS lD E O f CASE
K I C I C I Q A R O
S D E
MOtOING
sniP
1 D RA W ER G U ID E '\
(ClOSS 5 E C I 1 O N )
~ 2_
AGUR( 10
:K )
V E R T I C A L
RU fR S TR IP
fanTom
{ 00lN1HOI
w,
onSMITN
DRAWER GUIDES
' 'here are a rew m ore details to take rare
o f. F ir st .
drawer
g uid es a re m oo nt ed
in
side
the
ease to a lip created by
the
mold
in g
.trip:; (1) .
see Fig .
1 0 .
T he se g uid es
, sl of a run ner
and
a s id e g uid e,
To make
th e
drawer gu ides .
first cu t
th e
ru nner s I.
lr
id e and the side
gu ide s
(M)
I Mde . Then cut both to le ngth
to
fit
between
the back
edge
of
th e
filler strip
( .1 ) an d the ca bin et b ac k (C ), s ee Fig. 1 0 .
N ow
glu e th e
runner (L )
to the to p
e d g e
of the molding
.1til
(I) on th e inside or
the ki ckbo aI '( I f rame, see Fig. 1 0 . T hen
glu e a side guide (M ) on top
of
the
runner.
M ake sure both the runner
and
;de gu ide
are glued
t ig ht < \I fai nstthe end
panel
I 'lU . R S T RU '.T o complete the draw er
opening, I g lu ed a v ert ic al filler strip (K)
at each end
of the
opening see Fig. 1 0.
(N o te that the gr.un on this strip runs the
sam e direction as
the
fro nt o f
the
ease.)
G l ue t he
strip to
the en ds
of
t he o pen in g
50
they 're nush ith the front
panel
(8).
THELID AND TOP FRAMJ
The
li d
fo r
the chest is
mad e from so lid
s to ck . a nd to pped w it h a scroll ed fram e.
rn~ uo, Start.by edge-gluing'
enough
stock to make a lid blank (N ) tha t' s
l1 lughl y 2 8 w ide and 39 long. 'V ben the
blan k Is dry and planed
O at .
cut
it 1 1 1 -
Iarg~r
(in both dil 'ection. .) than th e
ease,
se e
Fig.
ROt r r P llOF I t . il . N ext. rout a Roman
egee
prolile
around all four edges lea\ing
a \I..
~houlder .
see
Edge
Detai l
in Fig. 1 1.
S CROu . .E O
FRAME.
' 'h e sc ro ll ed fra me
on
top
of
th e li d
COl l -< I s t s
of
three
piece,;
that
are m itered at the
b a c k
e em ers, ' 'h e
back p ie ce (P ) i ut to a w idth of S o
and
the n m itered to
length
(f rom l on g p oin t
to
l on g p o in t)
> 0
it's 1
V
I~$$
tht tn
t he l en gt h
of thP tid . see
~ ilt. I.
T he two side pi eces (0 ) are cut
to
a w id th
o f
:r .
S i ne (: t he se p ie ce s ar e onl y m itered
on the buck comet, fi rs t
cut .
miter on
000
end
of
ea ('h
piece.
'' hen tr im the ot her end
straight
I\()
tho di st ance from the l on g p oint
on
th e
mil. the ' ron t edge is
lil.
les s
than
th e
wirllh of the ti d , see ~ 'ig . 1 1 .
SC II O I .L W O R K .
A fte.
the pieces ar e cu t
to
.ize.
th e
8 :1 011d es ig n c an
b e
c u t a s
w a s
d o n . e m the kiekboard. Drill
ou t th e I
holt ,
make
A
pattern (see Fig. 1 2)
a nd
ttanl'rcr it
to
th.
wo rk pie ce . T h en c ut
out
and .and
th e
d,,, ,ign.
Al>- '
7/24/2019 Woodsmith - 058
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WOOD SMITH
THE TR AY
A ll t ha t' s l ef t
the ches t
a re
th e tt-.lYand
tbe drawer . J started on the tray .
DSS IGN .The tlllY
is
ac tu ally a tt-a ditional
dovetailed drawer,
bu t
with a twist. On
a
typical
draw er, the front fac es th e
D.'ont
of
the
case. But on this tray, I had to con-
s tr uc t it SO th e front a ct ua ll y fac ed
the
side.
The
cr itical
measurem en t
on
th e tra y
is
its dep th (from front to ba ck in sid e th e
case). Since it's easier to cut a drawer front
to a p recise length than it is to make the
overa ll d rawer length a
p recise
fit
1 jS\
tu rn ed th e d raw er sideways in th e c ase .
CUT1 J i 1 : I'IF;Csg. S tart building
the tray
by cutting. tray fron t an d ba ck
(Q )
(Whic
a re re ally 0 )1 th e sides ) an d tw o tt-.lY s id es
(R). A ll four p ieces a re cu t from ~ stock
to
a
w idth of 3~ , see Fig . 14.
To determ ine the exa ct length of the
D'Ontiback pieces (Q ), measure the inside
dep th of the cabinet (n'Ont to back) and cu t
th e tray s Ji'Ontiback y , less. T hen cut
the tray's side
pieces
to a length
01' 2() .
so ur DOV lTA U .s .A fter the pieces ar e
cut to
size, rout i d ov eta ils to join the
(OUI' pieces.
00
pages 20
to
2J .
sorroa, Now , cut groovesfOI the
v
p ly wo od b ottom (S) an d then cut the bot
to m (S) to fit, s ee D e ta il in Fig. 14.
THE DR WER
Next I
b uilt th e
drawer,
'l'h is time, it' s
o rien ted in the traditional direction.
I started by m aking a rabbeted d raw er
front ('1') f rom 414stock . To determine th e
w id th of the D'Ont, measure th e height of
the op ening and ad d
%
(for tw o
%
rab
bets).
>
subtract
V .
(for clearance).
M for the length of the drawer front,
f ir st mea su re
the w idth of th e o pe nin g.
Then ad d
%
fo r the ra bbets and subtrac t
(for Y ,,f clea ran ce on both sides) ,
pnOFlL E EDGE .Af ter the drawer front
is cut to
size, ro ut a shouldered round-over
on all four edges, see Stell J in Fig. 15
'Ihen
rout.
0/ .' rabbet aro und th e back.
S ho p N ote: I ro uted the r abbet in tw o
passes. First. set the fence for a shallow
bac/aoard
(le ft to right) sc orin g pass to
preven t chipout , Then move the fence an d
make a full % w ide cu t.
CUTOTHER PIl CES. When
the
drawer
front
is
com plete, cut the sides
(U)
an d
back (V )
to
size from
'h th ick
stock.
JOINRY \Vhen all the pieces ar e cut,
rou t dove tail joints Oil th e COM let'S (see
page 22). Then cut gr oo ves fo r th e drawer
bottom (W), and cut the bottom to lit.
1 ULl.S. B efo re as se mb ly . I d rille d shan k
holes to mount U10carv ed (o r brass) pulls,
see Fig . 16.
If you 're usi ng c arv ed pu ll s, y ou hav e to
drill c orresponding hole s in the bac k of th e
p ull. T o d o th is, cl amp the pul l
in
pla c e a nd
m ark the pilo t holes on the pull w ith an
awl. Then dl;1I th e p ilo t holes in ea ch pull.
V R A ET O N
AU FOUR S iD ES
PUllS
CK
D @ A W E R
NOTE ,
U TMean N
TW O ASSES.
seemr
NOTE,
t O J T INDS ARST
T O P tttVEtfT
CH1 PQUf
STE P 2
ST EP
W'
D O V E T A I L S
TR AY 5 S FAC E F RO N T
AND BA cte O F C HES T
NO TE ,
SIDE
BOTTOM
v,. ptYWOOO. CUT
ro
FIT) _
X~R O N T
18 /..
SIDE
FIGURE 4
7/24/2019 Woodsmith - 058
9/24
9
\ ' : lOOSMITH
0 T. y m. mack (2)
y,
X
3
/2 - 18/,6
N
T , Side< (2)
;;x3'h-20
S
1iay i ltom (I) '/4 ply. 18
1/,6 X
t
9Y
,
O C..... f
t(l}
171 '6 X
6 - 33 1.
N
U
Oro~r
S id c tS ( 2)
v x5 1.-19
v
Oro\Wt Batie
1
~ X
SV..-
321/a
W O n r w .
Boltom (1)
'/ .. p ly . 1 B V.. X 3 2
T
B
A
A
A
G
H
Fj:
A
A
0
R
0
0
B
0
L
N
,
v z z w z z
u
'M.- 11 7';''' 96
C
p
c
Tro y 8olfom (S ) and
Drawer 8oHom C W ) cut
f r o n
48 JC 48
~
of V . ptywoocI
u
v
$Mlf {OJ (:I.It fro m
24~43 ,,, I
01 Jf. plywood.
CUTTING DIAGIIAM
atmR MORTISE
O N n U CK N E $.S
O F F R ON T P AN E l
R OU T O UT
SHAUOW
M O R T I S E
FOR P lA TE
R O U T
DEE~
M O R T ' t s 1 i
100 l O N G U e
o
Ce:NTER
U N E
Of CHST
Non;,
LOC K
MORnSE
wla SE
OFfSfT
ON CH EST
C RO SS S EC TIO N
F I GU R E 1 7
D E T A I L
CENTfR P IN
SH OULD
ON SA CK
O N
fOOl OF ntlM SUGH1I.Y
PASTW
TOP
1ltlM
C f N TE R I .I D
ONCAse,
l A
I It
W
LONG.
ROUT MOR nSES
O ~
J4-
rO N
SuGHn y t.SS
MOImSE
WIDTH HINGE
THANKALf mE
O UT B AC K
E N D P A N E .L
lH I(KH ESS Of
ED GE
K NUC K LE
A
End P a ne o ls ( 2 ) 0 / 1 0
x
17- 20
B
Fron, Panel (1)
/,6 X
10
1
1._35 /.
C
Bad e Panel (1)
1)/16X17 - 3SV.
0
S h ol f ( ')
A N
ply. 19
1/.
x
34.
E TroyRunners (2)
''1 '00 x
0/..-
34 ;'
F
Top T rim
,/.. xl /16-10ft.
BA Se
G f
7/24/2019 Woodsmith - 058
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WOODSlvUTH
DADOS .Befo re a s sembling the fram es, end. Then three m ore dadoes are la id o ut
r
sw itc he d o ve r to
\\,0. [
flO f'
VIEW )
holds the face stiles
(D ,
E) to the side stiles
ONOUfS,IOE ~
FACE~S
;---
..
-'1 'I.- 1 -
RAaIIET fO R
(C). This is a combination of a rabbet with
ft .Y W O OO BA C K
To p ~
tongue and groove joint, see Fig. 4.
III
t 1
If .:
I.
he first step
is
to cut a groove on the
f
~
--
i-,-- c
nside face of the face stiles
(D ,
E). Posi-
( . 1/.
tion the lip fence S A > the distance to the out-
1
~,,:.
DETAi l
side of the blade equals the thickness
O f
CU T
'tWo
MIRRORED
the side stile (C), see Step 1 in Fig. 5. @
s s r s
O F 'A C E $ 11 lES
(Note; Be sure this groove is cut on the
FRONT
~
~
1
~I/
face with the foW'dadoes.)
FAC E
@i~
A B B ET N EE DE O.
The next step is to cut
STILE
: v , . I.
t-
. . .
- - 1-- -
a rabbet next to the groove. This rabbet
fRONT
OSedn the sides of the dresser,
OUTSIDE EDGES
FAa STilES
To prevent this, r cut a rabbet the same
UK<
?
/J
F I G U R . E 4
RABBET /G ROOVE
@
depth as tbe dadoes on lhe inside face of
Hl.ONJFAce
JO INT
@
each face stile (D, El). The side stile (C)
USE f liP
sn~
snu
then
fits
into this rabbet; and hides tbe
F iNCEA S
c
SlOi
T O P
STOf'
t- .
R 3 l
adoes, see Fig. 4.
~
RONT /BACK
_':;S
A C S S T I l E S
-
I~
ClTI RABIlET.
To cut the rabbet, ,,,ii\(
the dado blade
%
high, see Step 2 in ~'ig.
f-9--~
I/,L
1 . . A i
F-~___
~ ii( :
y.xv.-
5. Then a;are cut,
MEASutfME'NT
~ _ _ M A Y V A R Y
sembled, glue
and
clamp them to the rails
- 20 ,/ 5 11 GH n y
(A and )3 ) and the plywood panel (F) to
~
o r a side frame, see Fig. 6.
,- @---
Shop Note; Before gluing these frames,
CARp( TA .. A
e-, ...-
.
double-check to make sure you have two
STR IP
Of
WOOD
0./
mirrored sides and the roP label on all ONtO EDGEto
. . . _ _ . _ _ _ ~
four stiles is actually on the top. Once
flRO lCT G R OOV E
;;
r
HILE ctAMPlNG
-
~
everything
is
lined up, glue each side as-
M A K E S UR E S lO E ) _
. . . . . . _
. . . . . . . .
sembly together with the pieces flat
.. ~
R A M l IS fLA t FR OM
.
ro d
to act as an axle pin through the eye
bolt, see Fig. 7. (Shop Note : You can cut
tbis from a long rod, or nOOln the un
th readed
section of a ( ,boll)
EYE BOLT.
The eye bolt is just a stand
ar d 0/,( X
5' eye bolt purchased Dooma
hardware store. After using the jig for
awhile,
J
discovered that the eye section
started to uncurl when extreme pressure
was applied to the
cam.
To prevent this,
ha d it welded shut, see Fig. 7.
7/24/2019 Woodsmith - 058
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WOODSMlTJ:
8
TEMPLATE
After the jig base block and esm s were
comp le te .l b egan
work
on
th e comb
tem
plate
th at g uid es th e
ro ute r.
N ote: W e're
o ff er ing a p re -cut
plastic
template
in
a
kit
(see p a g e 24 ), bu t y ou can make your OW h
fi'Olll ~ \ faRon i te .
This t emp la te must
be
extremely accu
rat e
or
t he dovet ai l jo int w on 't
fit together
co rrectly , I found that the most ac cura te
m eth od o f cu ttin g th e n otches in th e
co mb
wa s
to
use a box jo in t jig . To bui ld a box
joint jig . se e Woods ,; No.
42.
CI)T N01C1IES .Sta rt by cutt ing a piece
o f M a so nite 4 w ide an d 24 long, see Fig .
S, The next
step
is cu ttin g the notches.
Since a W d ov eta il h it use s a 1 1 , (out
side
dia me te r)
router gui d&
bushing ,
th e
notches h av e to be ex act l\ '
0 / 0 .
w ide.
(Check the w idth cut
by
y ou I' d ado bla de
by m ak in g a noteh in a
test
piec e an d se e
if
your
guide bushing
fits.)
W hen the notch w idth is
C01'1 'OOt,
raise
the blad e 1 high and th en screw a ta ll
a uxil ia ry f en c e to tb e m ite r gauge. Now ,
stan d th e M aso nite o n ed ge and cu t a notth
6 fro m O ne en d, see Fig . 9 .
U lJ Il~G KBY.After the first notch is
cut.
cu t a v . . . in de xin g k ey an d glue it
into th e notch in the f ence , see F ig . 1 0
Once the gl ue d rie s, trim the top of th e k ey
slightly and cham fer the edges so the
workpiece will slil ov er it .easily.
Then, mo ve th e fence OV ~la nd s cre w i
to th e mitel gauge so th e key is i r J I c t l y
1 1 . from the dado blade. (N ote: T his dis
tance has to be extremely ac curate and
m ay take some
fi ne
tuning. The
b o x .
joint
jig shown in
Woodsmill t
No. 42 has an ad
justable fence that makes this adju stm en t
easier.)
cor RIlMAIN1NC NOTCHES.Ooce
th e jig
is s et. up , p lace the fi rs t no tc h o ve r th e key
and cut se con d notch in the template.
(Note:
I
backed up the workpleee w ith
another p iece of v .i Masonite 0 0 p revent
chipout. Then contin ue this process unti
fourteen
n otch es are cut, see Fig. U .
T o cheek for aeeurscy,
measure
the dis
lance f ro m th e
fil :lt
notch to the last. Since
t .here a re fo urte e n
?/j, ..
f,, \\ id e no tches a nd
thirteen 'I.. -w ide p ins, it should measure
11
Y o see Fig.
8.
ROUNOTHl: PINS. Once all the notches
ar e cut, ] f iled the front en d of each p in
rou nd, see Fig . 1 2 . (Note: The bac k end o
the notches on m ost comm er cia l temp lates
are also rounded, but they don 't have 0
be to e ut d ove ta ils .)
CU1 'TO
LENGTH.
To cu t th e temp late to
leng th , p lace it
0 1 1
the base block w ith the
m id dle p in
centered
o n the leng th , see F ig
1 3. Then mark and cut the temp la te the
same length as the
to p
o f th e base.
BRACKET S . The tem p la te is a tt ac h ed 0
Lhe b lo ck w ith angle bra ckets. T hese can
be
made from 4 x 4 s te el c orn er brack et s.
P O S m O N
ltM . PlA tE R U SH
W IT H E N D S O F A S E
COUNtQS INK HOlS
lE M Pl A lf fOR l
C i
_Fh M QiINECR~S
STUD
D E T A I L
V
CUT OFf
3
lONG
.. .--MACH IN SCREW .
lfAVE A R
lON G ' STU D
, -
. ; . - , , , - _
.
CUT T EMP lA T E
f lU H Wlnt 910
Of BASE
W IO T H
Of
S t , O T
SHOULD MATCH
O lA MF ftR O F
HOU; ~am
CUTOff
W A S T E
( wAST t em p a :t e
t o w a r d
yo u ..
'ro o SHilLWW. If 110tdeep
81Wag k, 'nU1ve t o w a r d ji g .
roo
LOOSE . If
join t . 'is to o
loose, in c r< ' < l$ 8 il d e pt h.
roo TI;llr. lf (I 8 jo in t is
I t ig ht , d ec re ase dep th .
S< ttingup to make router-cut dovetails is
always a trial and en-or effort, There's usu
ally lots of fiddling around with trial pieces
and l'eadjusUng to get
perfect fit.
roo LOOSE. the joint
is
so loose ehat
the pieces wiggle around when they're put
together, the depth of eut, is too shallow,
see first photo below. I n c r ea s e the depth
of cut about
v
and try again.
roo 'ITGB'I'.Ifa trial cut is so tight that
the pieces can't
be
tapped together, the
router bit
is
extended out too fur from the
router b a s e . D ecrease ehe depth of cut
about
Vd
and
tl
again.
roo DEEP. If the pins on the drawer
sides
go
to o far into the SOCketson the
drawer front, the sockets are to o deep, see
middle photo on right. To correct this,
move the template out (toward you) by
turning the stop nuts on the studs counter
clockwise.
Be
sure to adjust, the nuts on
both ends of the jig.)
Note: You may want the pins to be
recessed from the ends ofthe sockets about
.o t. This helps when sanding the joints
flush later. (See T i p s page 23.)
roo SHA/..WW. If the pins don't go far
enough into the sockets, move the tem
plate in (away from you) by turning the
stop nuts cloekwise.
OFFSET.After the joints are cut and
tapped together, sometimes the top edge
of the draw. Iront doesn't align with the
top edge of U,e side, see third photo.
If both the top and bottom edges.are off
set equa l amounts, there could be a couple
of things wrong. FiJost the edges o f both
pieces have to be light against the stop
block. There might be some sawdust b e-
tween t.he workpiece and the stop block.
Second, the offset on the stop blockmay
not be exactly
V a
If it's a little more
than that, you might
try
adding a layer or
two
of
masking
tape
to the finger on the
stop block.
Note: The end of the stop block should
be centered on the first notch of the tem
plate, see Step 4 on page 20. If it's not, the
top edges of the two pieces willbe a l i g n e d
but the joint won't be symmetrical on the
top and bottom
e d g e s .
OTHER PROBL.ThfS. M,ost other prob
lems are usually caused by the pieces no
being clamped down in the jig so they are
flush across the top, or because they mov
out of position as they're being routed.
TROU L SHOOTING
9
FinaUy remove lie (mllpiate alld
check (hat
I
of lte
8()(Jk~ ts
mid
p in.5
(, re I t iform . O ppos i 1 e . io i n t s a l' e cu t. on
th e w il t s u ie
of
the ji g .
10
A ft e r aU jo in t s a re ro u ted , cu t bo t
to m roov
0 1
S lt
l?l t1QO
P W; S e .
to
, atcl. drawer bottom
thickness.
Cen
te r tire
g l O ( J l J e
o n
the bottom sock~t.
TAlII
S W
StO'
eon
SO KT
F N
7
o p ..
e l J e > I .
c/lipout 01 1 d '' ( ~e> 'ide,
s/art. by maicblg a li g l l t p as s from.
1igll t to w f t . . This V groove est/,blishes
a. clean shoulMr liM.
Next, ..woo the router from wft to
right 100rkinDin mut oul of th e
1 I0 te he l l. P I< h t he r O I U e into _ ,,,,te h
,,, ,ti t. th e
bushing h its tlte b o tto m of .tolelj.
M A l < E U G H r P A :_ S S
1 0 P RE V EN T CH IP O U T ...
th O OV ErA ll B IT
pass from right to left, see Step 7.
Then gently m o v e the router in and out
of the fingers, moving
f rom
left to light,
se e Step
8 .
You should be able to feel the
guide bushing stop at the beck of each
notch. After routing, but before removing
th e pieces from the jig, cheek that you've
l O U l l ld each socket evenly, See Step 9 .
ROUTING RRMA1NlNG JOINTS. At, this
point, you've routed
the
joint
at
the left
front corner of the drawer. (It's marked
No.
1
in Step
1
Next rout the right rear
corner joint,(marked No.3) using the same
procedure.
M o u n t
the
d ra we r
side on the
o-ont of jig, the drawer back on the top of
jig - with the bottom edges _ ainst the
stop on the li if and the inside. facing out.
The other two joints (No. 2 and 4) are
routed with the pieces tight against the
stop block on the rigltt side of the jig.
Again, always claml) the drawer side to
tbe
jhmt
of the jig, the inside of the
pieces facing out, and the bottom edges
a .rinst the stops (this time on the right).
IVben routing on the right side, follow
the same procedure. Make a light
p a s
ss
from right to left and then move the rout r
in and out of the notches from left to right.
BO'M'OM
GROOVE.
When all the joints
are routed, aU that's left is to cut the
grooves for the draw. bottom, see Step
10. Cut the g.-ooveso it's centered O il the
bottom socket of the drawer
front
Then it
mil
be
hidden by a pin on the drawer side.
7/24/2019 Woodsmith - 058
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W O O D SM IT H
R ETEDDR WERS
M a kin g th e d ov etail joints f O J a drawer
with a a b b e t e d front is a little different
from routing a flush front draw. , You
have
to
take into eonsid e r a t ion the lip
arou nd the outside of the draw er front,
LAYlNG 0\11 . W hen you layout the
p ie ce s, th e w id th
of
th e
drawer's back an d
s id es h as
to
e qu al th e
.hOld(ler-Io ,shm 4er
widt h of th e drawer ll'Ont in stea d of th e
c ve ra ll w id th , 'l ee S te p 1. A nd the length
of
th e back e qu al s t he
shoulder-to-shoulder
length of th e f ro nt, no t th e overall length,
(I cu t th e r ab bets bej'ore routing,)
N o te : Onc e a ga in , it s best if th e c ab i ne t
is
designed so the w idth of th e
drawer
back
an d sides is
a
mu lt ip le o f 'I. ,
SPACER. W hen clam ping the drawer
(r(JnL to the jig, yo u also have to take into
cons ide r. . t ion the rabbe t. '1'0 co rr e ct ly posi
tion th e shoulder ill relation to the tem
plate, [ pu t a s pa ce r between th e drawer
f ront and the stop b lock, see S tep 2.
To determine the thickness
of
this
sp acer , s uo tr . . c t th e width of the rab b et
D '9m
V , ,
(since a pin plus a
notch -
Y o ) .
For a
,..
bbet then , y ou will need y,
s pace r, s ee
Step ~
END ALIGNMEI fl . O n the end o f th e
dr awer f, 'ont. the sltouJde,' of the ,.. bbet
(not the end ) ha s to be aligned w ith the
(,'O ntof the jig. 1 0 'let th is u p, c ut a m atch
in g rabbet i n p ie ce of scrap ana clamp it
under the front pressure
bar,
Then bring
t he r h. .
wer
front up
ti~ht agai,,~t
he ,
- a b
b et in the
scrap, see
S tep 3,
ROU I ING SIDEl;, AIle,' ,'Outing th e
drawer n'Ont (S tep 4), rem ove the front
f ro m th e
top
of the jig and replace it
,vith
a piece
of S 'I'8I),see
Step
5.
Then bring' th e
drawer side up tigb t against the
front
of
the jig and the scr ap , S ince tile side piece
d oes n't h av e a
rabbet
in it, you can rou t it
w ith ou t a s pa ce r,
BACK CORNERS,The back comers
(where th e drawer back meets th e sides)
al-e eut with th e
flush
doveta i l technique ,
s ee p ag e 20 ,
onOM GROOVE
T he r ab bet also has to b e c on sid er ed w he n
locating the groove for the b ottom in all
th e pieces, T o d o th is, I just av oid th e nil).
b et by m aking a little fence for the tab le
saw
that
fits
1mder
lh e rab bet, see S tep 6,
T he n th e g ro ov e will
be
cu t the sam e dis
tance f rom the shoulde r on the drawer
5 -on t a s
it
is f ro m th e b otto m
on
th e b ack
an d Sides, s e e S tep 7,
W h en cu tting a gr oov e f or a
v . r
plywood
bottom, r do it
ill
two s te ps, F ir st. a dju st
th e f en ce IO the cu t w ill b e slightly of f
centered 01 1 the bottom socket. A f ter
m a kin g a p as s w ith a U th e.'pie ce s, m o ve b h e
f en ce s lig htly u ntil th e g ro ov e is c en te re d
on the socket and w ide enough to accept
th e V . , bottom , T hen m ake another pass,
8
T ap d ra llJ CI 'sides iulo
< / 1 0
front
umil I} e
pins fit flush w ith the
S/tollktel'. T lte b ack jo in is cuI the same
a s for a. fill h f ro n /, d rawer,
1
o ,d
the
bottom
{ lroove on V 'C ;,..
side
of lite c lrcuvcr sides
(w d
o w ; k .
lea ve lite rip fen ce a'ut Masm,ile , , , , , , c . . .
in th e .a m e p osiu or:
1 1
R BBfTED
OR w tR FI lO W Y
TA P P fN S
IN fO S O CK ET S
U NTtl S lO IS flUSH
L E V E F ENCE ~
AND B lOCK IN
SAME POSJTrON
AS~~
IUU l , _ )
6
To cu t g ro ov e f or b ot(6 1 . , a it a s tl 'i p
o j M o so n i l e to
the
botU
oj' a block
a.ut ckmlp It)
f e n c e .
Theu.nm th e 'ubbe
.h m ll de r ga i,w t t il e M a S O Il it e
5
nemoue 1 1 , .
drawe r front mul
l I P l a c e
'willt a pi.c~ of 8 0.1', T h e n . 1'OU th e
l)i/l8 61t tile euds of ih d'' };lool' sitl. (I,.
. ((nU) M a ll . a
f l ,
fron: dllllvel ..
1 1
-
4
Cui the
,~(l(;ket.
in
I I . dra wer fron:
( iI mouillg TO ute r p 'Om lef t
I
,igh t.
Work il l (l'ut
ou t
Ih~ IIUicif & sltill{l
bottom . ou ilt al l of tl te l/ol e.< ,
To keep tile ..IUflddelof rabbel al ig>1e1t.
R BB ETED
ONT
7/24/2019 Woodsmith - 058
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However, J usually fo llo w th is secon d
m ethod and cut the joint so the pins are
about V,, too deep . B ut take this into
cons id er at ion when meas ur ing and cut ti ng
the draw er fro nt an d bac k to le ng th. fth e
pins ate se t V., too deep , th e length o
the draw er front and back w ill b e sh ort
ened
v s
whe n b oth en ds are sand ed.
arou nd th e pins an d also in t he s ocke ts.
usua lly use a s mal l r uti st'~ b ru sh to d o this
Tile problem
is that there are
a
lo t o f su r
faces
to
COveran d
the
g lu e c an s ta rt
se
ting
up
before you
can
get the draw er as
sembled. It's
a
good id ea to h av e SOmeh el
to spread the glue quickly
S NDING THEJOINT SMOOTH
T he p erfe ct d ov eta il joint should fit to
g eth er tig ht, flu sh , an d th ere shouldn t b
a l ot o f e xc es s g lu e s quee ze -ou t. That's th
id eal. B ut in reality , there m ay be som
finishing work to do on a dovetail join
a ft er a ss emb ly .
In fact, since I know the joint w on't
b
perfect, I plan tbe fit of the joint so it ha
to be sanded down exactly sm ooth. Th
on ly ques tion here is: Should the joint b
cut so the
1 ill
stick up a little from th
surface, or so th e
c U li s o j l it e s o ck e/ .
stic
up a li ttle?
S AND ING P INS , ff
the joint is cut so th
pins-stick u p, yo u have to san d th e ,q / tOl
d ra wer sid e to k ee p it a u nifo rm th ick ne ss
If you only sand dow n the face of the pin
(neal
the joint), the m id dle se ctio n o f th
draw er sid e w ill
be
th ick and cause pro
lem s w hen it's tim e to fit the d raw er in th
cabinet.
S AN 'D ING O R AWE B J;JNIJS. If the joint i
cut SO the pins ar e deep, then you onl
have
to
sand the ends of the sockets (the
ends of the drawer from, and back). B u
th is creates another problem , The fron
and back ru- eu sually cut to leng th to fit th
opening in the cabinet I there w i l l be
sm all g ap on either end. fy ou s an d afte
the d raw er
is
assem bled, the gaps can
e as il y g et
too
large .
However, even w ith light tapping , it's
best to ap ply even pressure across the
w bo le jo in t to p re ve nt th e p in s fro m sp lit
t in g ou t.
r
p lac e a b lo ck o f h ard wo od o ve r
all the pins on the drawer side and then
tap u ntil the p in. are seated
in
t he bo tt om
o f th e so ck ets .
ST NLeY H lttMJl Instead of
using a..
steel hammer 01 wood en ma lle t, I'v e f ou nd
t ha t a S ta nl ey De8(1B low hamme r wo rk s
n ic el y for most j oin t a ss embly ta sk s. These
h am m ers are m ad e o f b la ck p lastic a nd
the
head is filled w ith oil and shot They Call
be
used
with
quite so me fo ree a nd still n ot
dent the wood. They 'r e a va il able at m ost
h ard wa re sto re s an d h om e ce nte rs,
NO Cl-AlIfPS . O ne advantage of having
t igh t f it ti ng j oi nt s is that you w on't need
cla mp s to h old th e d ra wer to geth e)' w hile
the glue dries . (C lam ps c an so me tim es
have the negative effect of pulling the
d rawer o ut o f s qu ar e.) fth e jo in ts a re c ut
w ith a tight fib,
just
ch eck th e draw er fo r
square as soon as the joints are tapped
home. Then allow the drawer to dry on a
Oa t su rface ,
GLUING DOVET ILJOINTS
How much glue should be applied to a
d ov eta il jo in t? A nd wh et sh ou ld y ou ] lu t
it - on the pin s o r in Ille so ck ets?
TIGHT JOINT. If th e join t f its tig hUy , y ou
d on 't n eed m uc h g lu e. I u su ally sq uirt o ne
d ot o f y ello w g lu e o n th e b
7/24/2019 Woodsmith - 058
24/24
lOT IJ '>8F.D ovetail Jig Parts and W ood
Kit
($54.95) includes th e p ar ts in K it l If fi SE
plus all of the w ood (hard m ap le) needed
to b uild th e
jig:
(1 pe.) 1% x 6 x IS ( Bas e to p ).
(2
pes.)
1%
x
1%
x
15 (Bars).
(I
pc .)
1%
x
1%
x 1 6 V : .
(Oams),
1 pe.) y. ,
x
b
W x
2 . 2
(Base).
l
pe.)
II . x 2'4 x S
(Stops).
TEIIWLAr ONLY. f you want
the plas-
tic com b
dov etail
template
only .
Order
Kit #58C,
Dovetail Template,
$24.95.
OOVETAILorr. W e' re also
c)ffeling
a
double-fluted,
carbtde-tlpped 'A' dovetail
bit. It's a high quality bit w ith a 1 1 . shank.
O) d.1 Kit #58H ,
'J ,
Dovetail
Bit,
$1{ ;.75.
O RD ER IN G IN FO RM A nO N
To 0111erany
0
th e kits, w rite y onr ord er
an d yo w ' n a m e and a d d re s s o n a piece of
p ap er (o r,
if
availab le, use the order form
o n th e p ro te ctive covel' o f th is is su e). S en d
YOIU
orden a nd p ay men t,
(110
ch arg e cards
or phone orders, p lease) to :
W ood .m ith K its
P.O. B o x 10350
nes M oin es, 1 A 5 00 06
Please spee if y t he kit nu m ber on the out
side of t.he envelo pe . A llo w 4 4> w eek s for
delivery. Postage and handling are free.
(Iowa
residents add 4%
sa le s ta x.)
Plio
es
o f t he se
kits
ru... g oo d thr ough Decem ber
31 , 1988 .
on the hope ches t,
Order
Kit
#58C,
Hope
Ches t Pattern, st.oo.
DRESSER
W()() ( ismi lh is also offering a ki~ of hard
ware for the dresser.
KIT
5 8 1 > . Dresser Kit
(~6.95) includes:
(6 ) S olid B rass D raw er P ulls, w ith
00
ramie rosettes, 3 bor e .
I)
PI astic Buttons (drawer stops).
15 reet of G lid e
Strip,
se ll-adhering;
pressure -sensitive
plas tic ,
I .
wide ,
D O VE TA IL J IG
We've also p ut to geth er tw o d iffe re nt ki ts
to build th e dovetail jig.
K IT #58 e. Dove ta il Jig Part s K it ($3 4.95)
includes:
(1)
Do ve ta il C o mb Templat e. plas
tic,
o/ i' I
x
4 X
I S / .
(4 ) Eye Bolts , 0/ ,01 'x 5 ,
lvith
eyes
welded sh ut.
(4) Threaded Inserts,
0 / , , , ' in sid e dia.
(4) Com pression Springs,
%
x
2 ' .
(4) Steel Pin s, ~ x 10/. .
(2) Pan
Head
S crew s, N o. 1 0 x
Y .( .
(2)
Machin e S crew s, v . { x
3 .
(8) Hex Nuts, '/'1'.
2 )
'II W in g Nots w ith
w a s h ers ,
(4) Fh.
Macli ine Sc rews, V x 1 4
(4) Fender W ashers, 0 /0 , x
10/,r
(2) Corner Brackol. 2 )( 4 X
tN
aluminum with slot an d holes .
KIT N l8B. H ope Chest K it (B rass P ulls)
(~.95)
include s all of the item s in K it
#58A , ex cept the pU ,lI sare m ad e of Solid
Brass, 2% x
4 /.
see ph ot:o abQ ve.
PATTERNONLY. If
yo u
only want the
fl lU-si1 .epa tt.e n1 S o f th~ scl'lllwol'k de.~igns
HOPE CHEST
WO O f lsm ilh is o ff eJ in g two hardwa re kits
fo r (he
hope
chest. One
has carved cherry
pulls, the other solid b rass pu lls.
K IT # 6 8A . Hope
Chest K it
(Wood
Puil$)
($34.95) includes:
l pa ir ) So li d
Cherry
Ha rdwood Pu ll s,
2'~'
x
9 % ,
se e photo below.
These
pulls are hand carved in the Amana
Colonies in Iowa,
(I pair) Solid B I O S S Hinges, 1 V .
long, Z open w idth,
\\~tJj
screws.
(1
pair)
Lid Supports.
on e rig ht- hand,
one le ft -hand, b l O S S plated, w i t h b l' 8 S S
screws.
(1 )
Chest
Lock,
key, str ike plate, and
k e y h o le escutcheon.
(1)
Full -s iz e Pa tt er n s of scrol lwork.
WOO SMIT KITS
eyes from co m ing uncurled.
Cut four 'h, x
1%
steel p in s fro m
a V i' steel rod or [rom the unt.hreaded
part of 0 . 4 carriage bo lts .
M ake tw o
2 '
x
4
brackets from
4
x
4 C O m e r br ackets, s e e page 18.
GUID&BUStliNG. ')'0 use
th e dove ta il ji g
you
need a V , .
outside diam et er
guide
b u sh in g ,
Bush ings
ar e
m ad e
to
fit
specific
ro uters, so ch ee k w ith a d eal e r who carries
accessories for your
router. /\
universal
bu sh in g' set is avai lable from :
WOOOCRAI 1' suppx,y CORP.,
41 A tlantic
A v e ., P .O . B o x 4 0 )0 ,
WObUi'Il,
M A 0 1 88 8 ;
800-225-11 53 (Catalog : F r e e ), Rotder G uili 'ls
(1 pai r), br 3SS
pl ated, 6'h long, 01 1le1 ' No. 01205.
CllIlst Lock,
include s
key and es cu tcheo n,
Ord er No. 03304, Carved H art lw(I ( ) ( lP u l l s
(2), 1% hig h, 4% wide , Chen-y, Order
No. B12OO;'V aln ut, Order No. B
l2oo ;
Oak , 0111er No. B1204. AnOLhel' option
would be to use
brass pulls (see
pho to
bel ow ): Sl (W Puils (2 ),
:r
bore, 4%
overall , O rd er No. Ell2.3 .
DRESSER
Y ou
can
ord er the
dresser
h a rd w a re I om
W oodfnni lh se e be low ), or fr o m :
our es