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SHELF ETEVANG{S AND CUTNNG DETAII.SIq.Ii'"-li'"-li'"-lF'"-lf '"-l['"-lNote: All dadoes shown are %"'wide x 1/q"'deepAuxiliary fenceRaise the %"dado blade tocut a rabbet in one edge of each rail.Allow %" ior the dado in theend panel. Use a spacer to layout the first dMder dado. Gttt thisdado in all three shehes. Wth the saw tumed off'set a dado in one of theshelves over the blade. Thenrcposition and lock the fence withthe spacer betrveen the fence and worftpiece.rail for the back panel (nlc. 6).Thencreate a tongue on both ends ofeachrail to fit into the groove in the endpieces (nIc.7).DAIrc FOR IIIE DIVIDERSFor the drawers of each size to beinterchangeable, the dividers betweenthe drawers must be evenly spaced.Todo this, I used a 3"-wide l.rardboardspacer as a layout and setup gauge.First, use the spacer to lay out thedado closest to the right-hand end ofone shelf (SHELF ELEVATIoNS andCUTTING DETAILS).Then align thelayout lines with the dado blade andbutt the rip fence agair.rst the errd ofthe shelf. With thc fence set, cut the"first" dado in all three shelves (dadoboth faces of the nriddle shelfl.Here's where the spacer cotttesinto play as a setup gauge. By usingit to reposition the fence after erchseries of cuts, your dadoes will bespaced exactly the same.Once you've cut dadoes for thesnrall drawer dividers, lay out and cutthe dado between tl.re large drawers.To lay out this dado, allow for the'/u" that fits into the end partel.Thensplit the renrair-rir-rg space in half.WORK ON THE RAITSNow work can shift over to the rails.l3egin by rabbeting one edge ofeachASSEMBLE IHE CABINETIt'.s easiesto assemble the cabinet ina specific orcler (CARCASE ASSEM-BLY VIEIJV). First, apply glue to thedadoes in the end panels and clarnpthe shelves in place between thetlr.Next, apply glue to the groovesin the end panels and slide the bottornrail in from below. Tl.rer.r slidethe back and top rail into place fromabove. (You nray need to loosen theclamps slightly to get the back piecesinto place.) With the clamps still inplace, dril1 colrntersunk screw holesrnd screw the back and end panelsto the shelves.DRAWER GONSTRUCTION VIEW@Front/backcBottomCsioeCard holder pullwith screws#17 x3/+"Wire brads@Front/backWith the drawerfront/tack blankripped to width, cut agrcove for the drawer bottoms.54wotTKBENCH ! JANUAIT.Y I FEBRUAI{Y 2000
GARGASE ASSEMBLY VIEWStep 4: Addsclews toends and back.Step 3: Slide backpanel and upper railin from theStep 1: Glue shelvesbetween end panels.Rabbet both endsof the rails to fiorma tongue. Make testcuts so the tongue fits the goove.Step 2: Slide lower railin from the bottom.The tlnal step is to install thedividers. Chances are the shelveswill have bowed slightly, so measurethe height of the outerrlost dividerlnd cut thcrrr all ro this sizc.To install the hardboard dividers,turn the carcase on its back andapply a snrall ar.nount of glue toeach dado. Then slide the dividersinto place, leaving theru flush withthe front edge of the shelves. If rrecessary,you can clanrp the shelvestogether to close up any gaps rharappear above or below the dividers.MA!|S PRODUCE THE DRAWERSWiththe cabinet completed, it'stinle to trlrn your attention to thedrawers. Arrd herci where it rerllypays off to ltrove into a mass productionmode.For me, the key to mass producingsr.nall parts is to start by ripping longblanks to width. From these blanks,yoll then crosscut the parts to consistentlengths using a stop block setupand the miter gauge.Before cutting the drawer fiontsand backs to length, though, you'llwant to cut a groove for the bottomsdown the lengths of these blanks(FIG. 8).That's a lot easier than cuttir.rga groove in the 32 smaller pieces.Once you've grooved the blanks, cutthe pieces to length (FIG. 9).There are a couple nlore cuts tonrake before the drawers can beassernbled. First, cut a rabbet on bothends of the front and back pieces(FIG. 10). Then create a tongue oneach end of the drawer bottons bycutting a'/," x'l." rabbet (FIG. 11).Finally, assemble the drawers withglue. I used wire brads to hold thesides to the ends and bottoms whilethe glue dried. That elirninated theneed to clamp up each drawer.flNAt STEP!iTo protect the organizerfror.r-r shop grime, I appliedtvvo coats of oil finish. Afterthe finish dries, card holderpulls can be screwed to thefront of each drawer. Onceagain, I used a sirnple jig (acright)to position all thepulls unifornrly.Like most organizers, thisone only works ifyou use it.But with valuable shop timeat stake, you shouldnt needrnuch incentive. tm-A simple iig centerc thecad holder pulls.Install the pulls withscrcws to keep themfirmly fastened to thefiont of the drawen-- Wldepush blockUse a stop block on your rip fence tocrrsscut the drawer ends to uniformlength. Use the same technique for thebottoms and sides.Use a wide pushblock to firmlywhen you cut the rabbet for the sides.Rabbet each endof the drawer bot.The tongue should be %" thick.WORKBENCH tr JANUAI{Y I FEBRUARY 2OOO 55
Page 1 and 2: THr OnIGINAL WooowoRKING RT.Ip Horu
Page 3 and 4: (lQuestions &Answers- 72llao,,fl)sP
Page 5 and 6: Feedback & Follornr-UpSuruey Says:
Page 7 and 8: uestionsa& Ans\MersScribe the Base
Page 10 and 11: Tips &TechniquesPrecut Doonvay Bott
Page 12 and 13: Use A Framing Square to Locate Gent
Page 14: News & EventsMedium-Density Fiberbo
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Page 28 and 29: MATERIALS LIST — TV CABINETLUMBER
Page 30 and 31: Plate joiner>r BasicsAnytime you're
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Page 36 and 37: Storage Made SimpleFor about $100 a
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Page 56: ,-H-

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