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Grid Details
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Front and Back Grid
strips for the grid pieces and for
the pegs (Figure 7). To ensure
that these strips can't be kicked
back, use a push block that passes
through the blade with the strips.
Now carefully glue each grid
assembly together.
Squore Peg Holes
Forming square holes for the pegs
is a snap if you have a hollow chisel
mortiser. This tool drills out most
of the waste and squares the sides
of a hole in one step. Fortunately,
you can get the same results with
a drill and sharp chisel.
Iay out the peg hole locations
on the frames (Frame Details).
Then draw lines from corner to
corner to mark the center of each
layout. Chuck a1/qt'bit in your drill
and bore a r/arldeep hole at each
layout (Figure 8). Square the
holes with a very sharp l/+rr chisel,
taking your time to keep everything
crisp and even (Figure 9).
As you proceed, dry fit a peg
strip in the holes - you want a
snug fit, but not so tight that you
need a mallet.
Square up the peg holes with a sharp
chisel. As you work on each hole, test its
size with a %" Peg strip,
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Grid Mortises
Now that you have the hang of
forming square holes you can
move on to forming mortises in
the frames for the grid installation.
Before you can form these mortises,
however, you must rabbet the
back of each frame opening
(Frame Details). Use your router
table and a rabbeting bit, making
sure the bit's bearing limits the
width of the cutto 1/+rr (FigUre 1O).
Rout the rabbets and square the
corners with a chisel, then lay
each grid into its frame and outline
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Use a push block that can travel through
the blade while ripping the grid stock to
width. This will prevent kickbacks.
/+" Chisel Rout /4" deep x 7n"
Set up your router table with a rabbeting
bit, then rout the rabbets around the
opening on the back of each frame,
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the mortise locations (Figure
l1). Drill out the mortise waste
with a r/qn bit, but this time drill
only 1/6rr deep. Square the holes
with a chisel, making sure to
check the fit ofthe grids as you go.
When everything fits, put a spot
of glue in each mortise and press
the grids into position. After the
glue sets, rip l/srr-deep grooves in
the frames for holding the bottom
(Frame Details). You'Il need to
make two passes with a standard
blade to cut grooves wide enough
for the | / 4n -thick hardboard.
Drill holes 7a"
deep, centered
Tq" Forstner
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Begin forming square holes for the pegs
by drilling with a %" bit. Be sure to align
the bit with the center of each layout.
The easiest and most accurate way to
locate the grid mortises is to position each
grid and draw around the ends.
W'orkbench r December 1997
33