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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.

7/24/2019 Woodsmith - 054

3/24

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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11/24

_'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

7/24/2019 Woodsmith - 054

14/24

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

7/24/2019 Woodsmith - 054

15/24

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

7/24/2019 Woodsmith - 054

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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

7/24/2019 Woodsmith - 054

17/24

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~~~~ ~======~~~~~~~

7/24/2019 Woodsmith - 054

18/24

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

7/24/2019 Woodsmith - 054

19/24

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;.