DIY Network

Egyptian Dresser, Part 2: Side Frames and Panels From "Wood Works" episode WWK-708

	The Egyptian-inspired mahogany dresser.

In this two-episode installment of Wood Works, David Marks builds an Egyptian-inspired dresser with slanted angles and cove-molded top. This first episode is devoted to building the dresser case, making the side panels and attaching the base of the dresser.

In this second segment, the focus is on the construction of the side panels.

Tools and materials used in this episode:

Mahogany stock
Maple stock
Oak stock
Ebony stock
Maple plywood stock
MDF for templates and mockup
Table saw; cross-cut sled
Tapering jig
Multi-router
Jointer
Power planer
Table router
Biscuit jointer
Drill press
Clamps
Yellow woodworker's glue
Slow-setting resin glue
Hand scraper
Sandpaper, various grits
Straight-edge
Carpenter's pencil
Safety glasses or goggles

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

advertisement

	Figure A
	Figure B

Side Panels

The mahogany stock for the frame-and-panel sides is cut to the following dimensions:

• Top rail: 15-1/4" L x 1-5/16"W x 7/8" Thick
  
• Bottom rail: 15-1/4" L x 3-1/16"W x 7/8" Thick
  
• Stiles: 26-1/2"L x 2-1/4" W x 7/8" Thick (figure A)

• To join the stock for the side frames, cut mortises using the multi-router (figure C). The mortises in the top-side rails and stiles measure: 5/16"W x 3/4"L x 3/4" D. The mortises in bottom side-rails and stiles (figure D) measure 5/16"W x 2-1/2"L x 3/4" D.

  Figure C

  Figure D

  
  

  
  

• Secure the panel in the panel with cauls and clamps while the glue dries (figure K).

• Use plenty of clamps to ensure a good bond all the way around the frame. The cauls will hold the panel in the frame while preventing the clamps from marring the surface.

• Allow the panels to dry for at least three hours.

  Figure E

  Figure F

  
  

  
  

• To join the basic frame together, apply yellow glue to all the mortises and tenon stock (figure E).

• Assemble and clamp the frame (figure F), check it for square and let it cure.

  Figure G

  Figure H

  
  

  
  

• Once the glue has dried, use a 1/2" rabbeting bit at the router table to cut a rabbet on the inside of the frame (figures G and H). This rabbet will be 1/2" wide by 1/2" deep, and will hold the plywood side panel in place. For safety, cut the rabbet in several passes by gradually raising the bit. Use push-blocks to keep your hands away from the cutting surfaces.

• Use a sharp chisel to square the corners of the rabbet.

  Figure I

  Figure J

  
  

  Figure K

  
  

• Take exact inside-measurements of the frame (figure I).

• Using those measurements, at the table saw, cut some 1/2" mahogany plywood to snugly fit the rabbet.

• Apply yellow woodworker's glue to the inside of the rabbet and install the panel (figure J).
  

  
  

• The next step is to cut the matching angles so that they will line up with the case. Set the table saw blade to 7 degrees (figure L).

• Angle-cut the top and bottom of the frames at the table saw using the cross-cut sled (figure M). The 7-degree angle cut on the top and bottom of the side-assemblies matches the tapered angle cut earlier in the frames.

  Figure L

  Figure M

  
  

  
  

• With the angles cut, the side assemblies can be glued to the case. Apply yellow glue to the edges of the tapered stiles of the frame and the edges of the side-assemblies, and set the side-pieces in place (figure N). Since this is a long-grain to long-grain glue-up, the glue bond will be strong enough to hold the components securely.

• The clamping strategy for this assembly is very important. It's important to have even clamping pressure along the whole glued surface. In order to accommodate the angle, use tapered cauls as shown (figure O).

  Figure N

  Figure O

  
  

  
  

RESOURCES :

The Small Wood Shop (The Best of Fine Woodworking)
Author: Helen Albert (Editor)
Publisher: Taunton Press
ISBN: 1561580619

Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456

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

Fine Woodworking
A magazine devoted to high-quality craftsmanship in woodworking.
The Taunton Press Inc.
Website: www.taunton.com