Build the Box

Before I cut them to size I need to get the surfaces nice and flat. To do this I start out with a scraper to remove any excess glue from the glue lines.  ss_06_scraper.jpg

3-Piece Cabinet Scraper Set
3-Piece Cabinet Scraper Set
 

After all the glue is removed I run the panels through my planer taking off just enough wood to insure that they are smooth and flat.

ss_07_planer.jpg

Cut the panels to width and then using my tablesaw sled, RunnerDuck Project, www.runnerduck.com/tablesaw_sled.htm, I cut all the pieces to length. Setting up a stop-block on the sled makes the job quicker and more accurate.

ss_08_cut_length.jpg

Mark the locations for the biscuits on the front and back and then transfer those lines to the sides.

ss_09_mark_biscuits.jpg

Cut the biscuit slots into the ends of the front and back.
Adjust the biscuit joiner to a height that will allow the front and back to align with the sides allowing for a 3/16″ setback.

ss_10_biscuit_cut.jpg

Cut a groove 1/4″ up from the bottom of the front and back. The groove should be 1/4″ deep and wide enough for a 3/16″ piece of plywood. I used my router with a 3/16″ bit set 1/4″ high.

ss_11_bottom_groove.jpg

I put a 1/8″ round over bit into my router and radiised the front and back edges of the sides.

Round Over Router Bits

Round Over Router Bits

ss_12_radius_edges.jpg

Cut the legs into the ends leaving 1/4″ between the bottom groove and the top of the radius.

ss_13_cut_legs.jpg

Sand everything smooth and do a fit check before gluing. If you are happy with the way things go together apply the glue and clamp.

ss_14_glue-up1.jpg

 Apply glue to the biscuit and put it into the slot then spread the glue along the edges. Apply glue to the protruding half of the biscuit and to the matting edge of the wood.

ss_15_glue-up2.jpg

Place scrap wood under the clamps and clamp everything in place to dry.

 

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Published in: on Sunday February 25, 2007 at 2:04 am  Leave a Comment  

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