DIY Network

Egyptian Dresser, Part 8: Top Assembly From "Wood Works" episode WWK-709

	The Egyptian-inspired dresser made predominantly from solid mahogany.
	The actual top of the dresser is made from 3/4" Honduran mahogany plywood.

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In this special two-episode installment of Wood Works, David Marks builds an Egyptian-inspired dresser. In this segment, the dresser's top is assembled.

Tools and materials used in this project:

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
Lathe
Table router
Plunge router
Dovetail jig
Biscuit jointer
Drill press
Chop saw
Clamps
Yellow woodworker's glue
Slow-setting resin glue
Japanese hand-saw
Dead-blow hammer
Brass pins
Hand scraper
#80 cabinet-scraper
Sandpaper, various grits
Straight-edge
Tape measure
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.

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	Figure A
	Figure B

Dresser-Top Assembly

When gluing up the pieces of the coved molding, use custom-cut blocks -- hot-glued to the corners -- to give the clamps an even surface to grip onto. Additional blocks added to the inside of the corners will provide some additional support help to keep the structure flat and square. David opted for a slow-setting urea resin-glue for gluing up the miters. This type of glue allows time for adjusting the fit of the pieces during glue-up and provides additional bonding strength.

A band-clamp is used to pull the cove-molding components together during glue-up, while bar-clamps can be used to provide a secure joint at the miters (figure A).

While the glue on the molding is drying, the support ribs for the top may be cut from plywood. These ribs will span from the front to the back of the cove-molding frame to support the actual dresser top. At the table saw, cut 3/4" into strips, then cut a 30-degree angle into the front ends. Then cut a 90-degree notch (figure B) to accommodate the 1/2" plywood attached to the cove molding.

Figure C

As seen on the prototype, the actual top of our dresser is made from 3/4" Honduran mahogany plywood. The raw ends of the plywood are banded with a 3/4" solid-mahogany frame that's 2" wide (figure C).

Steps:

• At the table saw, cut the plywood for the top to size.

• Using the miter-jig (figure D), cut miters on the ends of the milled frame stock (figure E).

  Figure D

  Figure E

  
  

  
  

• Biscuit joinery is used to join the top to the frame. Using the biscuit joiner, cut #20 biscuits all around the frame stock (figure F). Then cut matching slots in the plywood top.

• To glue up the top, apply yellow glue to the edges of the top and frame stock as well as the biscuit slots (figure G).

  Figure F

  Figure G

  
  

  
  

• Position the pieces and align the corners using a band clamp. Then apply even pressure using bar clamps (figure H).

• While the top dries, you can attach the cove molding to the case. First, glue a sheet of 1/2" plywood to the case to level the surface (figure I) and secure it in place with screws.

  Figure H

  Figure I

  
  

  
  

• Carefully align the cove-molded frame so that there is a uniform reveal surrounding the top (figure J).

• Trace the position of the aligned molding (figure K).

  Figure J

  Figure K

  
  

  
  

• Once the position is traced out, apply yellow glue to the base of the cove-molding assembly (figure L) and around the top.

• Position the cove molding to the proper register (figure M).

  Figure L

  Figure M

  
  

  Figure N

• Once the molding is in position, apply downward pressure with clamps (figure N).

• Allow the glue to cure overnight.

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

Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
Model: 080836878
Author: Rick Peters
(2000)
Sterling Publishing Co. Inc.
Website: www.sterlingpub.com

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