| Magazine Storage Boxes -- Cabinet Assembly |
From "Wood Works"
episode WWK-408 |
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Case Stock and Assembly With the individual magazine-storage sleeves made, work can now begin building the walnut case that will house them. Materials: Table saw
Table router; flush-bearing bit
Plunge router
Yellow woodworker's glue
Safety glasses or goggles
Note: Cut sizes may vary. For exact measurements, please contact David Marks through his Web site -- information below under Resources. Safety Alert: Always wear safety goggles or safety glasses when working with wood, power-tools, saws, drills, routers, etc. Steps: - As seen on the prototype, there is a 1/4-inch reveal along the edges, and the sleeves are set back an additional 1/4-inch (figure A). To figure out the overall measurements of the case, use the dimensions of the sleeves. The objective is to create a case that allows the sleeves to slide easily in and out, but prevent having a fit that's overly loose.
- To get a good fit, line up the four completed sleeves with 1/32-inch shims placed between them. Then take an overall measurement of the width (figure B) and height to determine the inside dimensions of the case.
- Once you've determined your measurements, trim the width of the case stock at the table saw. To keep the glue-line centered, trim both sides of the stock.
- Next, cut the rest of the case stock to final dimension on the table saw (figure C), referencing your measurements.
- To bring the sides of the case together, use mortise and loose-tenon joinery. At the ends of each side piece, two mortises are cut 3-1/4 inches long by 1/4-inch wide. The back mortise is laid out 1-1/4 inches from the back edge, followed by a 1-1/4-inch gap (figure D), then the second mortise.
- To make the matching mortises in the ends of the sides, place the stock in a workbench vise, and clamp a wood-block onto it to support the plunge router (figure E).
- Make the mortises in the top and bottom of the case stock (figure F) with the fence of the plunge-router adjusted to allow for the 1/4-inch reveal.
- We made our tenons from a strip of Peruvian walnut. Each is 3-1/2 inches wide, 3/4-inch long, and 1/4-inch thick. The edges of the tenons are rounded, using a 1/8-inch round-over bit, to fit the curve of the mortise (figure G).
- With the joinery for the case complete, conduct a dry-fit to ensure that the pieces fit together properly, and that the sleeves fit easily inside. Before glue-up begins, layout is done for the rabbet that will hold the back panel of the case (figure H).
- At the router table, cut a through-rabbet 1/2-inch deep by 3/8-inch wide in the sides of the case stock (figure I). In the top and bottom case-stock, cut stop-rabbets.
- Apply yellow glue along the edges, in the mortises (figure J) and onto the tenons.
- Once the sides are in place on the bottom piece, carefully add the top (figure K).
- Clamp the assembly carefully using wood blocks to protect the walnut (figure L). Be sure to check for square as you apply clamps
In the segment that follows, the back panel is added as well as brass hardware and a tung-oil finish. Sponsored Resource
> Click here to order your tools and materials for this project from Woodcraft!
RESOURCES :
Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com
The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619
David Marks Website
David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
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