DIY Network

Egyptian Dresser, Part 3: Back Panel, Runners and Base Construction From "Wood Works" episode WWK-708

	With the inside case and outer frame complete, work can now begin on the inside of the dresser.

In this two-episode installment of Wood Works, David Marks builds an Egyptian-inspired dresser of mahogany. With the inner case, outer frame and side-panels of the Egyptian dresser complete, work now continues with the back panel, runners and base construction.

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
Hand scraper
Sandpaper, various grits
Yellow woodworker's glue
Slow-setting resin glue
Straight-edge
Carpenter's pencil
Safety glasses or goggles

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Figure A

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

Back-Panel, Runners and Base

• Once the side-panels have been glued in position, and the glue has fully dried, use a hand scraper to smooth the edges where the frame meets the case and level the transition (figure A).
  

  
  
  

• Measure the inside of the case to determine the exact length of the runners. The runners that will hold the drawers start just inside the face frame and run to the back of the case.

• Measure the back of the case (figure B) for a panel-stop that will keep the mahogany back-panel in position.

• At the table saw, rip the runner stock from 2"-thick quarter-sawn oak to the appropriate length -- 17-3/4". We selected oak for the runners (figure C) because it is a hard and stable wood, and because drawer-runners get a lot of wear.

  Figure B

  Figure C

  
  

  
  
  

• Once the runners are prepped, cut four smaller pieces for the back-panel stops.

• Re-set the fence and rip four T-shaped runners (figure D) for the middle drawer and four L-shaped runners (figure E) for the top and bottom drawers.

  Figure D

  Figure E

  
  

  
  
  

• Use the drill-press to make and counter-sink three 1/8" holes in each runner. Also drill equal-sized holes in the stock that will hold the back panel. Once complete, attach the back-panel stops along the back of the case using yellow glue and screws (figure F)

• At the table-saw, for the back-panel, rip some 1/2" mahogany plywood to size.

• Set the back-panel and drawer-runners (figure G) aside for now. Before installing them, you'll need to complete the drawers. If the back-panel were in place, it would be difficult to reach inside the case to attach the drawers.

  Figure F

  Figure G

  
  

  Figure H

  
  
  

• Work can now proceed with the base. As seen on the prototype, the base is made from solid mahogany and frames the entire case assembly. It is 4-3/8" H x 43-1/4" L x 20-3/4" W (figure H).
  

  	Figure I
  	Figure J

  
  
  

• To make the base, cut some 1-1/2" mahogany stock oversized. You'll need two pieces that are 44" long and two that are 22" long (figure I).

• While the stock is still square, use the table saw to cut a rabbet in one side of the base stock (figure J). This rabbet should measure 1" W x 3/8" D -- wide enough to support the entire assembly.

• Tilt the blade to 45 degrees and miter-cut the ends of the stock to match the case. We used a mitering sled to hold the stock securely while making the cuts.
  

  
  

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