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Trophy Case Take a look at some more manly cabinet projects from Man Caves. From "Man Caves" episode DMCV-112

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Figure C

Attach the top case to the main case:

9. Set the top case onto the main case so that the ends of the end panels line up flush with sides and back edge of the main case. Once you are satisfied with the fit, connect the two with wood glue and 1-1/4˝ wood screws. Drive the screws through the nailers into the top panel of the main case. Make sure to pre-drill and countersink the nailer before driving in the screws (figure C).

Attach the back panel:

10. Cut the back panel (1/4˝ plywood) to size according to the cut list. Attach this panel to the back of the case using the 18-gauge nail gun with 1-1/4˝ nails. Start in a corner and square the case to the panel as you go. Continue nailing all the way around the edge and into the back of each shelf as well.

Attaching the face trim:

11. Cut the top and bottom rails according to the cut list. Attach these rails (top edge of the top case, top edge of the main case and bottom edge of the main case) using wood glue and an 18-gauge nail gun with 1-3/4" nails. Face nail the trim to the edge of the plywood. Try to limit the number of nails you use. Note: Keep the top edge of the trim flush to the top edge of the plywood you are attaching it to.

12. From this point on, you can refer to the cut list, but measure each piece of trim before cutting it to fit. Measure, cut, then attach all of the stiles (upright trim) next. Finish the trim by cutting and attaching all of the shelf rails. Note: All of the trim is 1-1/2˝ wide (1x2) except for the middle stile on main case. This piece should be 2-1/4˝ wide. See cut list.

13. Putty and sand all of the trim.

Making the doors:

14. Cut the door stiles and rails to size according to the cut list. Make sure the cross cuts you make on the rails (16-1/2˝) are exactly 90 degrees.

15. Cut the 1/4˝ plywood door panels to size according to the cut list.

16. Using the table saw with the blade height set to 3/8˝, run a groove down the center of one edge of all the stiles and rails. This groove should be at least 1/4˝ wide. Mark the center of one of the ends of a piece of the stiles or rails, and then line this mark up with the blade of the table saw. Move the fence over against the piece of wood. Now you’re ready to rip. This 3/8˝ x 1/4˝ groove or dado you create will eventually accept the 1/4˝ door panel. Note: If you don’t have a 1/4˝ dado, you will have to make a few swipes through each piece to get the width you need.

17. Using the Kreg pocket-hole jig with pocket-hole screws, join one of the 16-1/2˝ rails to two of the of the 32-1/2˝ stiles. Place the rail between the stiles so the long outside edge of the rail is flush with the ends of stiles. Make sure the dadoes are all facing in. Clamp the three pieces together and use the pocke-hole jig to drill the holes from the stiles into the ends of the rails.

18. Glue the joint and drive in the pocket screws. Repeat this same process to the other set of stiles and rail.

19. Slide the door panels into the grooves of each partially finished door frame. If the door panels don’t slide in fairly easily, just sand down the edges until they do. The fit should be fairly snug.

20. Tap on the remaining rail until it rests snugly between the two stiles. Flush up the rail with the stiles, and then join them the same way you did in earlier.

21. Check the fit of the doors on the front of the main case. If satisfied with the fit, sand then stain and polyurethane the doors.

22. Attach the hinges to the doors with the supplied screws. Now you can attach the doors to the main case.

23. Attach the door knobs to the doors and you’re done.

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