NOTES FROM THE SHOP

NO. 62

PROJECTS:
THREE DRAWER WRITING DESK
WALL UNIT WITH CABINET
WORKING WITH PLYWOOD:
CUTIING SHEETS INTO PIECES
. COVERING PLIESWITH
SOLID WOOD EDGING
FLUSH TRIMJIG

$3.50

Edi\O< Donald B. Peschke

DesIgn otretiOf Ted Kralicek

ManagIng Ed~", Douglas I- Hicks

Assistant Editors Douglas M. Lidster

Kent A. Bucf<lon
ProJeciDesIgner Ken Munk,,1
TecIv1lcalllluslra)OrsDavid Kreyling
Cilry Cl1rist.nsen
RodStoakes
Ohris Glowacki
CU__
Sandy,Baum,Mgr.
Jackie Stroud
Pat Koob
L.isaThompson
Project Supplies leslie Ann Gearhart
Terry J. Strohman
eori>pulerOpefalioljS Ken M1ner
AdminislJ1lliv<! Assls, t!:heeyl SroIt
Jean carey
Building Majnl"",,1lCC Archie Krause

WOODSMITH STORES
()peraJl9fls Steve Krohmer
Mari<Bllng
"""'_
Steve Dozier
$10mMangers:

St. Louis, MO Jon Behrle

'Bed<eley, CA Michael DeHaven
Des _ es, IA Kent Welsh
WOODSMITH (ISSt>[ 01611 14) is Rublished t)imonthly (FebfO~ry, APR', June,
Augusl,
October,
Oecember)
by
Woodsmith Publishing co., 220!) \3rand
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EDITOR'S

APRIL 1989

NO. 62

COLUMN

Saw-dust

n tile last issue 01 lVood$uth we lmroduced our new graphic style - the new
way the art and text are laid out on a page. I
was both excited and nervous about making
these changes. For ten years we've always
received very nice compliments about the
look 01 Wood$milil. So, my leeling was:
don'i change a good thing.
But the changes wfive madeare intended
to be improvements in the way the articles
are presented. Now thatwe have two issues
under our bells. I've been very happy with all
thechanges.They leI us presennhe projects
in a step-by-step lonnat thai's easier to read.
A-nd f think ii'S easier to see the, process of
howeacb project is buill.
Most o( the changes I talked about in the
last issue had to do with the graphics 0{ the
articles. Buuhereareseverat other changes
we've made - particularly in the way we
present wocdworking teehniques as-sociated with the projects.
Every project has-a lew interesting techniques orsome tiP.:$ t],t1l apply to many other
projects aswell. Inthe past, we've presented
these techntques right along with all the
other delails about building each particular
prciect,

That approach is okay- the inlonnation

is in the issue. But it's usually buried in (be
article. And, 10 be honest about it, if you're
not particularly interested in that project,
there's not much point in reading through it
justto see if there's a good tip ertwo buried
in there somewhere.
Anyway, we fell that there were a 101o[
good tips beiog missed. SQ. we decided to
l,ighlight these tips so Ihey're easier to find.
Actually, we're doing tlla( in two ways.
SHOP NO'l'S.First, we've added a regular
feature called Shop Notes. A1L1\oughthis
page has appeared in a few previous issues,
itwasnever the reguJe,rfeature\ve
it to be.

intended

11,. idea behind Shop Notesisto serve as

a collection of tips from the lVood"",ith
shop. As we're building the proiects lor an
issue, there always seems to be a few good
general tips we wantro show.
F<lrinstance, in this issue we've included
four tips that could be used on a varielY of
projects. How to install recessed wooden
drawer pulls, How 10 make a simple jig thai
helps align a router to cut a dado, How 10
mount false drawer fronts and gel them
aligned. And bowto rip thlnstripsof wood to
be used lor edging plywood.
11.. t'squite acoltection.ln the past. these
tips might have been. buried in the project
article. but could have been easily missed.
\Voodsmith

Now we're putting them in Shop Notes 10

highhghtthem a little more.
"p BOX~.Another approach we're experimenting WiUIis the use ofwhat we call a
Tip Box, I( we have a special tip for building
project, but tralso has general applicauons,
we wiU try to highlight itin 8 Tip Box in the
article.
For example. whet. we vvere assembling
the Wall Unit shown on page 4, we had to
glue and damp large pJywood sides to the
plywood shelves. To get even pressure
along the lenglh of the joint. Iused tapered
clamping blocks. These blocks are a nice
idea, so we put this tip in a tinted box to
highlight it a little, see page 7.
TECIlNIQUE ,\Rl'lCUS. 'Vhile I'm on the
subject, the one request we've had consistently overthe yearsis toshow more techniques on woodworking, In addlucn to
adding Shop Notes as a regular feature and

including Tlp.Boxes, we are also going to put

more emphasis on full..length articles on
woodworkiogtechniques.
In this issue for example, we've included
three articles on the techniques we used to
solve some olthe problems associated with
plywood. How to cut the pieces you need out
01 a large sheet. How to apply solid-wood
edging strips 10 hide the plies on the edges
of the plywood pieces. And a special jig to
help trim the edging strips flush wilh the
face o( the.plywood.
,'Ie will continue 10 present these technique articles in future issues. In fact, we
often cnooscprojecrsjusi lor the techniques
lhal are involved in building them.
SUPPUES. 11,o( takes care of most of the
major changes we've madeto lVood8mitkin
the past two issues. However. U1Cl'e'Sone
more small addition worth mentioning.
Along with the exploded view 01 the project. the cutting diagram, and the materials
list, we will always tryto include an inforrnation box on tb.esupplies we used to build the
proje_c~Specifically, we want to provide information on the lumber, tbe hardware, and
the finishing supplies.
We receive a lot of requests asking how
much it COSIS to build a project - particularly how much the lumber costs, Sincelumber prices vary dramatically around the
C().\Ul1.cy. \Vi; couldn't come up with one-easy
doliar 6gUl'e.lnstead, we decided to lis! the
number of board leet 01 lumber we used 10
build the proiect, A quick call to your local
supplierl\lill teUyou the price per board foot,
NID>TISSU.E.
TheJuneissueof WO(Jd~>nil"
(No. 63) will be mailed durinl1 the week of
June 26. 1989.

No. 62

FRO

FELLOW

WOODWORKERS

Tips & Techniques

ROPE CLAMP
U you 've ever glued up a frame,
and found tharyour web clamp is
lost somewhere. do whar j domake a rope clamp, This clamp
is made from 1"'0 readily available Items - a band screw and a
lengtb o( rope.
TIGHTEN Bone

HANOWAl
SAM nME

',,'

NYl.ON
ROPE

PlNCH ROpt
AT BACK JAW

To use this clamp. open the

front jaws while closing the
backiaws.so the clampforms a
"V". refer to Ihe drawing. Form

a loop with the ends of the rope

andlay ilona flatsurface. Now,
lay the "V" of'theclampoverthe
ends ofthe rope.

QUICK TIPS
Cut Plywood Easier
Cutting large sheets o( plywood
on sawhorses or just by yourseU
can bearealhassle. When J don't
have help. and I need to make
long cuts on a sheet of plywood.
I putthe plywood on top ora 41<8
sheet of Styrofoam bead board.
Set the depth of cut on tbe
circular saw so it cuts through
the plywood, but barely into the
bead board. You don't have, to
worry about the blade being
damaged in the bead board. And,
irs easy to crawl along the top of
the plywood to make long cuts.
Daniel Malin
SI1iUJ1.t6! Katl8(UI

Clean Shoulders
Whenever I'm handcutting
tenons, I've had problems keepiog the shoulders clean. The
blade alwayswanLSto wander off
the scribe tine rightatlhe beginning of thefirst cut

No. 62

GUIDE FOR HINGE MORTISE

Apply glue 10 the miters oflhe Cutting hinge mortises with a shouldersofthedado.
frame and ",ssemblc the frame. cbisel can be difficult. The probFinally.cutapiecefortheback
Then place Ille loop of rope 10m is trying to keep the andglueiUothebackedgeotthe
around the frame. Now. while shoulders of the mortises two width stops to create a "win
holding' the ends of the rope. straight and the bottom nat To dow"for the chisel.
slide the hand screw up close to help simplify Ulis task. I built a
To use the chisel guide, mark
theframe.
chisel guide.
the location of the hinge. Now
To keep the ends of the rope
The guide is made rv;W;'iiS~f;;::;::=::::::::--f;~;:::;;n
(rom slipping through the out o( four pieces of
clamp, tighten down the back %'Cthick stock. One
handle so the back jaws pinch piece acts as an edge
the rope. Now. 10 get Ihe right stop against the face
tension around the frame, of the door Or stile.
slowly close both. bandies on the The other three
hand screw simultaneously.
pieces are glued to
OAI)O tQUA1$'
Marty RoboitlS th e top 0 f th e ed ge fHICRNES$
OF
Pleasallt Orova, Utah stop and guide Ole HINGt~F
(I)GfSTOP
chisel when outting t..::=:..::;::__.:::;::.::::::__~~~~
Editor'. Now: W. tried this the mortise's width and length.
look through the "window" in
rope cla-1rllp method: 11.s1.1tg
To make Ulechisel guide. first U,e guide and align the guide to
vario". types of rope. We ripapieceof stockl"-wide for the the layoul lines; 'Ihen, clampthe
[o">La Vt' nyl011rope W01'k.s l11e edge stop. Cut it to length about guide to (he work-piece.
oest. A>Ld, it's jairly cheap at 6" longer than the hinge.
To Cut the mortise, start by
abollt 30 cents p~1'foot. Also,
Then, Icut a dado in this piece oullining the three sides of the
~'-wid6 nylo't flat ,.ebbing equal to the depth onhe hing.e I mortise, First, set the chisel
uorks uiell; too.
agai nst the I WO
width SLOPS. and tap
on it to mark the
mortise ends. Then,
hold the chtsel
To make it easier to start the
against the lenglh
saw and to help keep the blade in
stop and tap down to
line while cutting. Icura starting
make a score line
trough with. sharp chisel on the
along
the length o(
1_1e side o( the scribe line. 1'0
thewindow.
do (hiS, just pare Straight down
To remove the
on the scribe line first. Then, wantior the.mortise, (A hinge is waste, chop a series ofrelief cuts
make a second CUI,holding Ihe usually sel into a mortise the along the length of the window,
chiselat a 45' angle on the waste thickness of one leaf.) The about every 1'16". refer 10 drawside of the score line. This length o( this dado must match ing alleft Then lay the chisel flat
creates a channel (9r the S3\V the length of the hinge.
in the dado in the edge stop and
blade so it rides in the score line.
Mer the edge stopis finished. pare straight in to remove the
Ra"dol~ Prestrcidg6 next cut the three pieces to form waste to the back of the guide.
Roger St-Denis
Shlltgarl, G",man'Y the U-sha~<I chisel guide. First,
two width stops are added to the
Ripon, Q,,,,bec
Dowel Centers
top oftheedge stop. Thewidth of
Dowel centers are useful for these pieces is critical because f-~5~EN=D:..!I~N:!..Y=O~U~R:!..'~I~P:=5~
marking matching dowel holes' thisiswhatdeterminesthewidth
J( you'd like' to share a tip
in adjoining pieces - if they of'the hinge mortise.
with others, send in your ides
don'tfalloutbefore making-their
To determine the width o( to llroods-",ifh. TIps & Tech.
mark. To prevent this, place a these two pieces. measure the niques. 2200 Grand Ave .. Des
pieceofmasking tapeaoress the width o( one leaf on the hinge,
Moines.lowa50312.
dowel centers. The points will and add I" (forlbewl6th o(the
We pay $15 (or accepted
still go through the tape and edge stop). Then rip the two tips. Please send an explanamake their mark.
width stops to size. Now. glue tion and " sketch if needed
Richard Do..., them to the top of Ibe edge Stop (we'll $frawa new one).
-'-_-l
Oel't.-ei1t,/OIIJa. so the ends -allgn with the L_-'-

~~~~i2::~':::::::::::_J
r

r-==:-::::-:-::==c==,---,

\Xloodsmith

FEATURE

PROJECT

Display Wall Unit

With just two and a half sheets of plywood you can build this wall unit.
The shelves are deep enough to display stereo equipment. And the doors at
the bottom make a nice cabinet to help conceal any clutter.

hen you set out to build

a large project like this
Display Wall Unit plywoodis an
ideal material lO work with. II's
flat, dimensionally stable, and
comes in sheets Jargeenough so
you don'I have to golhrough the
tedious process of edge-gluing a
101of boards together.

thickness throughoul the sheet

(usually due 10the final sanding

each sbeetgets). So. rather than

lake a chance on a sloppy fit, or
ODa joint line that look~ wavy. I

cut. v..widedado,and then cui

a longue to fiL
EDGING. ln addition to using
longue and groovejolnerv as the
However. there are two main primary joint to assemble the
disadvamages to plywood. TI,. ease.1 also used it to auach edgedges have to be covered in ing stripsto bide the edgesofthe
some way to hide the plies. And, case sides and shelves.
the project has to be designed
Allhough the edging could be
around the fact that plywood glued on with just " plain butt
comes in 4 X Bsheets.
joint. using a tongue and groove
Togetthe most.ifieient use of joinl helps align the edging.
each sheet, you hay. to juggle When you're worklng with long
the size of all the 'pieces 10 fil a pieces (a. on the fronl o( the
certain cutting diagram, I also ease), you need all the help you
had to watch the grain direction can gel 10gel those long strips
- especially with the doors. glued on - wiU,oul sliding all
Here Itried to arrange the pieces over the place.
on the sheet to gel the oicest
f'INlSH. When the case was
grain pattern on the two doors. done. I decided to npply two
JOINERY. After working out coals of Mlnwax golden oak
the cutting diagram. I bad to de- stain. Then I finished the Wall
terminethejoinery.1 decided to Unit with two coats or
use tongue and groove
McCloskey Heirloom semj.gbss
j 0 in I S throughoul this project, varnish.
beginningwil.lllbe primary joint 10 join the SUPPLIES
three fixed shelves to
thecasesides.
WMBEa
Tojoin these pieces.
l cut a v.... wide dado
1\.2SbeeIs'y,"-!hick oak pI).,,'OOd
across the inside
5Boan1feet'l',"-dlio.i<"liidoak
face of'thesides, Then 1Sheet II,' -thick oak plywood
tongues arc CUI on lbe
MAUWAH
ends of the shelves.
(See J>3lI" 24 for 101)
BUI why CUI a v...
wide dado? Why DOl 2 Recessed red oak door pulls
make it tit wide to 2 Pair pivot hinges
match the thickness of 12Brass shelf suppor1S
2 Adjustable leveler&
the plywood'
We used~" oak ply. 1Double piale magnetic catch
wood. which is rarely
FINISH
exactiy ~"thick - it's
Mlnwax goklen oak
usually just sligbt.Jy Slain:
Varnish:
McCloskey Heirloom clear
less. It ean also have
semi-gloss varnish
slight variations

Woodsmith

in

No. 62

EXPLODED VIEW

CROSS SECTION
SHUF
.~.

:~
)

:r

-:-----!:!~:.

RUl",
STRIP

--ifr-
a'

IDGING

PANn

OVlRAlL OIMlNSIONS: 80"H x 30-W x 161'0

......

CUnlNG

DIAGRAM

MATERIALS LIST

~'4")t r- . 86" i4,2 Bd. ft.)

ij

14~
:Ill -2".

~:,,"x 4' x

30"

t:

i
H

l'

D casoS.eIc(l)
~\x4~
:.:_4' PLYWOODSHiiT

8' Pt.YWOOD SHEET

ALSO

cZ

f-----------ic

:%

No. 62

B ~edSIleIYes(3)
G T:opI8lm.PnI. (2l

~.4.d. f',~
N

A Ca,eSidas(2)

F
E

1----,-'-----1
G

Woodsmith

RtQUI~D:
ONf4x8

.,...

SHEFrOF

PlYWOOD
fOR CASE:

BACK iQI

E TopAdi. SIleIoos(21
F BonomSllelr,(l)
G Ooo<s (2)
SOUD TRrM EDGING
H roplSoll"" (4)
1 Front SldIlS (2)
J rl1<edSbotI8S(3)
K Adj.51\01'"", (3)

'!I'pIy' j~ X7lI~
y,'piy '5*x 2914
;,,' ply. 2811 x 3l'.!

W ply 29l1x 7011i

ply'14~x 2m
plyWIt x 1311
~. ply-13W,oxZJj$
j;'

3','

~)(1 15Y"
~X180

l PaJle!~(2)
Ii TopPa.eITtim(lj

"'"I28
;-<X 128!i
~x~28
:y", 1 28

H AnerSllfp(I)

V i~28*

THE CASE SIDES

cerro SIZ.~To make the sides, first cuta
DAOOESFORSIIELVES.Mtercottingallthe
Istarted work on this
\Vall
Unit
by
making
large
blank
to

rough
width
of
34'.
and
a
tongues.
Icut three dadoes for the fixed
~
two
case
sides
(A).
finishedleng\hof19V,.see
Fig.
I.
(Seepage
shelves
(8)
across the Ill1l!e blank. FIJ'$l.
....
10for
cutting
plywood.)
Although the sides
mark the location of the three dadoes. see
-~
arejust two pieces of
TOSGl:S. Mtcr the blank is cot 10 size. Fig. I.Then clamp a straightedge fence to
plywood. they pre- tongues are cut on all four edges. Tongues the plywood blank and roul each dado. (In
senta problem. Each aroused to attach hardwood edging. refer to Shop Notes on PlIgC 12, we show a simple
side has three sets of Fig. 6. (Beginning on page 20. there's an ar- gauge to belp align Ille fence.)
dadoes for the fixed ticleaboutaddingedging to plywood with
CITl'CASE srues. Now to gel the two case
sides (A). I ripped the plyweod blank into
shelves (6) - and these dadoes have to be tongue and groovejoinls.)
perfeclly aligned so the shelves lay flat. The
Procedural Note: When I had the router two pieces. each 1~'1wide.
Irick is 10CUIthe dodoes across one blank of set up to rout the tongues, Iwent ahead and
BACKI'ANEI.. l~lSUh'T. ~J'\Clast tiling is to
plywood. then cuuhe blank in halftogeUwo
routed the stI111C tongues on the six shelves roul a rabbet on the back edge on each case
identical pieces. see Fig. I.
(8. E and I'). (See the section below.)
side 10attach the case back (I). see Fig. 2c.

...,
_,.

CASE SIDES
19'.-

r"

nNfSHlD--..
ROUrAlONO
STlAIOHTlOGI

FOURTH:
an ~."RAlIff

34" ROUGHWIDTH

u:MOTH

FOR IACK_:\

15([ fIG.

"'y

'."TONGUfS

'-...-'
't" .,""e.NT.....
r
_;:- ~, ON Pt..YWOOO

1 I...
,t-~
2.
....'0..~"
.
,I

. .-

FIRST:
ROUT TONoum

AROUND
(mlRt
ILANK (Sit
flO. -

::'' -A-'

SECOND,

THIRD:

ROUT"XlD SHELf
DADOES (Sit '10, jb)

I\IPTO 1.... ":::'''-_~

flNISHm WIDTH

__

./

THE SHELVES

~:r--,
Alter the case sides

are finished. work

can begin on tbe
shelves. There are
three 6xed shel ves
(6), two top adjustable shelves
(E). and one bottom
'----"f::""---' adjustable
shelf
(F). I started by cutting all six of these
shelves 10size. see Fig. 3.
lONGUES.Afierlheshelvesarecutlosize.
tongues are routed on Ihefr(mt edges of aU

,.1.

the shelves for the edging s\rips. see Fig 3.

Next. rout tongues on both "'Ids of the fixed
shel ves (6) only. These tongues fit into the
dadoes in the case sides, see Fig. I.
1lU)1 TONGl ..~ BACK.There's one more

step on the tongues. The tongues on the

front edge of the fixed shelves have to be
lrimmed back to allow space for the edging
when it's applied 10 the case sides. Trim the
tongues back v.." on both ends, see Fig. 4.
now FOR l'IV()1' !lrNCR.Later, when the
doors are mounted. r used pivot hinges 10
mount them, rererto Fig. 0\. The only prob-

FIXED SHElVliS
3 PlEas

lem with these hinges is tlt.IYOUhavetodrill

the holes in the bouom fixed shelf (8) before
the case isassembled.Il you dom drill these
holes now, you can't gel the drill close
enough 10 the comer after assembly.
Also. these holes must be drilled in the
right location (or the doors 10swing properly. see rig. 4. Mark the cenlerpoinl of me
holes 7". from the 1'11<1.hOllid..,. of the bot10m shelf and V," from the fronl shoulder.
Alter marking the location, drill the holes at
both endsofthe shelrto accept the bushings
for the hinge. S<!C Fig. 4.

80nOM

ADJUSTAIlLE SHELF
1 "'((I

~
I .... TOHGUl

AtONT

mG.

ONLY

, .~f-::=2~"~"
==!
!)

TOP
ADJUSTABLE SHElVliS

t
6

.NCIS

\'<Ioodsmith

curOACJ<
TONGut "'ON aotM NOS.
AU Rxm $HflVU

._

-, .

NOTE:
OMJ.HlNGE
HOU$IH

aonoM

SHRfONiY

No. 62

ASSEMBLE THE CASE

Once the shelves were made. I began to as- glue in the dado. 111en clamp the shelf in
semble the case. I started by getting. three place, checking (or square against the sides
clamps in position theflcor, spacing them witlt a Iraming square. Clamp the other two
so they would be in line with. the dadoes. fixed shelveiusing thesame procedure.
Then stand the sides on edge with tile fixed
As the clamps are lightened, make sure
shelves (13) loosely in place.
the (rant shoulders of the tongues On the
TAJ'ElttD BLOCKS.When you're clamping. shelves are Ilush witil tile shoulders of tile
wide pieces like these case sides, the clamps tongues on the case sides.
tend to apply pressure only at the top 5
and bottom of the
CHECK CASE
joint. but oat along
WRH SQUAilE
the middle. To get
even clamping pres-

0"

su re across

TAPERED BLOCKS
To get even pressure on the.entire I~ngth
of the tongue and dado j0int. I mail.
tapered clamping blocks. T11Ctapered
blocks are nothing mor. than lengtil~ of
2 x 2 scrap. USually you can find some
that arealready stighUy warped and form
a natural bow.
If not, use plane or belt sander to
create a bowed shape (rom the middle 01
the2 x 2 ouerotheends. You don'thave to
work too hard - about V.6" 1)(1' foot is
enougb.ltjusthas
to bow enough SOlbe
middle touches before the ends.

the

whole joint, I made

some tapered clamping blocks. (For

more information,
see the box at right.)
Shop TIp. When
using these blocks. I
put a small piece of
double-sided carpet
tape on the clamp
heads to hold the
blocks in place.
Wlten the clamps
and tapered blocks
are in place, remove
aile shelf and apply

IN
(' ~.~o~w:;c,~.:~r;AT(S
Of JOINT

-1TtM

CROSS SECTION

~lf

~~~~----------)

TAPR ClAMPING
BLOCKS, six PlEctS

FlAT SURFACE

CUT EDGING
While tile case was
drying, I cut 12 edgiog strips: four strips
for tile top and bottom case edges
(H), two lor the
front edges (1). and
six for the shelfedg

in each strip to fit over the tongues on the

case sides and shelves, see Fig. 6.Since tne
edging is I" wide and the plywood is only
:y," thick, thegrooves arecutslightly o((-<:en
ter, This produces a lip on tile inside edg'l! of
thecasesldesand onthe bottom aflbe shelves.
~
To cut the o((se~groove.1 used a V." dado
~
blade on the table saw set l"t6" deep, see Fig.
ing(J,K).
7. (The groove is VlG" deeper than the
cur EDGING.Start by ripping I" wide edg- tongue to allow a glue relief) Position the
ing strips from .,"dlick stock. Then cut the groove so the edging will stick just a hair
twelve pieces needed to rough length.
"bove the face of the plywood (about Y.l2'~
OWC.'ITER GROOV.Next, Icui grooves when it'sglued in place. see Fig. 6. Later.you

F=

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7
srr F(NCE

9J),"

EOGING .....

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F.ENCE

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No. 62

WOOd.(Iused a flush trirnjig, seepage 22.)

PRO"'LEEOGES.Afterthegroovesarecu~
round over the Iront edges olaU the edging
strips with a V4" round-over biton the router
table, see Fig. 8.
Shop Note. Since these edging strips are
fairly narrow. I used a.grout trowel to push
them through the round-over bit. see Fig. 8.
Although the round-over bit has a ball-bearing pilot, I used the fence to guide the long
strips. Align the fence with the edge of the
pilot. then push Ihe strips along the fence.

uS(
fATHERBOARD

fROM INStQl
EDGEOfBLA2

S.UGHT SHOULDER (1';;2".

call trim this slight lip flush with the ply-

DADO

BLADE

Woodsmith

EDGI N G

CONfI"'"IOO

I-""'ii::;;~----'A!tcr

making

the

edging slripS. I cuI

them 311 10 length.
_,
Firsl<:utthctopand
.--'
bottom strips (H)
so the ends align
~
with the shoulders
L____!~~~~~_JofthelonguC1ionlhc
sides. see rog. 90.
Next. CUIthe front strips (I) IMI go on
the Ironledges or the sides. and round over
Ibe ends.Also. since thegroo''e in this ,trip
extends through the lop end. CUI.fillerplug
10 fil this bole. see rog.9a.
Now. cut the shelf edng (J and K) 10
length. round over the ends. and glue it onto
the shelves.\Vhen gluing the fixed shell
strips on. the tipon the lop shclffaces up. The
6pson the middleand bottom sheJveo< tiJre down.
ORlWNG TMPIAT&. Afler attaching tbe
edging strips. Idrilled holes for the pin supports used to mount the top adjustable
shelves (E). To position the holes. I cut.
drilling template to fit between the top and
middle shelves.Then drill v.." holes. spaced
as shown in Ibe Cross Section.page 5.
Afterusing this template to drill the holes
in the upper section orthe WallUnit.trim it
down to drill the holes in the lower secuon.

:::r

...

....

(~

f1tONT
lOO.N<>
o,_

-........

"

"

i/

=;J

......

a.

PlOOfltONT
lDGlHO

toP/.ona""

V
0

SIOES

BOTTOM

fii

TOP AND BASE

~

rrne basic cabinet is

TOI' AND l)<YrTOMP"NELS. Afterattaching

the case back. Iadded the top and bottom
~"
panels (C). '111etop panel is culto fit behind
r.::;;.
the lips of U.e edging strips above the top
shell. see Fig. 10"Be sure 10 note the grain
~:.
iII":...
Cuuhe case back direction - this panel is only 3\.'t' 101lg be......~:...._......I
(0000) OUI.01 v." ply
I' cause the grain direction runs vertically. lrs
w
sou ms snug y cut wide enough to fit behind the lips o!t.be
between the rabbets front edllingstrips onthe sides.'Tbepanel
on back or the case sides. and between the on the bottom is CUI to fillbe same way.
top and bottom fixed shelves. see Fill. 10.
After culting Ihe panels to site. glue them
Then screw il into the rabbets.
in place behind the lips ofthe edging strips"

Cif]

completed byadding
the case back and
the top and bottom
panels.

ro

10

GW ......

C1M\.

r".....
.,..,..
....
_.,..".,
__

13
-I
" Ud--":"';,,'---l
~.

TOP AND

TO &NJoIDl UP

SPACERS. To complete these panels. I

added edging pieces made to looklikeall the
other edging. To do this. first add a spacer
(L) to the Illpedge orthe top panel. sec Fig.
U. CUI another spacer 10fit on the bcuom
edge or the bottom panel, sec rrog. 13.
Now. 00 the top panel only. cut a top
panel trim strip (M) J" wide (to duplicate
Ibe look of the edging) and round over the
front edges and ends wilh a V." round-over
bit Then glue this trim strip to the front of
the spacer (1.). see rog. 12.

BOTTOM

PANEL

TOP

!'I"

"__,

Ii c>:
~

_/<r-o
0

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11UM

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wrtH~OP~no,..,

'6 .. "."

wooosc:.rws

,~
CASE BACK

SH(lI-

.__
LL

CROSS
SECTION

'AHa

-..

BOnoM
P~1l

.. . o.

f'

~."
1--'

'IX[D

om

\'iloodsmith

aonOM

$P~tR

3l,.,~

PANt,

lOP
-flJClO

TOP

Sknyu

31,.
I

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PANR--+

SHW

:-

No. 62

THE DOORS
~

....

f.--J.
~
I.-' ~
.__~~

The cabinet is really

complete at this
point and could be
used as it is.
However, I added
doors(<?)tothebot.
tom secuon,
DOOR SIZES. To
determinetheheight

14

AJ.J..CNIl .... 'uAClNG

IlOUT "'.
-DrtPUCUS

uruSl.O
DOO<II'UUS __

~ ON AU. SIDlS AND "'\

......

InwtYN DOOaS

L. -........__,...::::::::-_
2Wo"

<f:;i'
~

......::....

DP'l_Y~~><?D

",.-"""'"

DOORS

1'0"-

I~

of the doors, measure between the edging

13','
8tril/8 on Ole two lower shelves. Then subtract
ror the 111" space above and below
......,~,
the doors. and subtract another WI" for the
111l"-lhickedging strips that trim the door'S.
"'(-;;'''I:!~K
To get the width of the doors. measure
ON AU 'OOlS
v _,_
between the edging sutpson the case sides,
SUblrdct~" (for the W spaces on eaeh side
,
,I
oflbe doorsand theone between the doors),
15
.

and subtract 1',' for the ~g

strips. Then
I-TlI'
C......
f1WII
divide by twOand cut the doors to width.
,
S1'IJII AGAiNST
DGIS(; STRJPS,Alterculling the doors to
Iii r- _ , u.o. ""'ING
size. Icutl16"-thick edging strips tocovcrall
four edges of the doors. (Refer to Shop
Noteson PQge 130n howtocut thesestrips.)
Altcrthe strlpsarccut,glue andclampthe
strips on the side edges of Ole doors first
,
:
f).
Then add the strips on the tOPand bottom
edges, Finally, trim ihe edges Oush with the
'f
faces of the doors,
,
1
FILl.ER
ruus, Before mounting the doors. r cui
"
STRIP
recesses for Ihe pulls and mounted them.
1
(Sec Shop NOles on paRe 12),
111-<".
~_I
IIINGES:n.C doors are mounted between
the two lower shelves with pivot hinges. The
holes for these hinges are already dnlled in
~~~:;_-'/
the bottom shelf,
As for the top holes, you need to add a
filler strip (N) behind the lip of the edging
a,
strip on themiddleshelf.see Fig. 16. Cut this
tlSAW
to ,.strip 10 fi~then drill the holes in the same
THICk
position as on !be bottom sheJf.see rlg.l5a.
., J,. HOtI
"
Then mount the hinges and screw
I,'
them to the backs of the doors, see Fig, 16.
lalsomountedadoublemagneticdoorcatch
~.ll
underneath
the middle fixed sheU.
see Fig, 17,

\I,"

I~
",__"'_~~Jb

I'"

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3'~...

WITH
toOING

I~ ,
"

'L

@
I

"

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~l
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I '

tf

~~p

T
,"'.1-'....,
,

CfMtRON

..

MlDOU SHUI __, ...

nwl
STlIlP

MAGNmC
CAtCH

LEVELERS
AJU,ough this Wall Unit may be perfecOy
square and kvel,lhc floori! rests Oil may not
be-espccinllylfthcunitisoncarpetingaod
against a wall, There's usually a tack strip
under the l.rpct ncar the wall. Thiscao till
thetopo(thc Wall Unit out (rom the wall.
To level it. 1added two adjustable levelers
behind the bottom panel, see Fig. 18.The
trick to adju<tlageach 1ev",ler is to drill a bole
through the bottom shelf for access to the
screw in the leveler. Locate this hole so it
alignswith the top ofthe serew, Thcnmount
the lovell...bracket to the bottom panel. and
level the Wall Uni~ Cover the aecesss bole
with the plug that comes with the leveler,

No.6Z

Wcxtdsmith