| Maple and Walnut CD Cabinet -- Top and Door |
From "Wood Works"
episode WWK-202 |
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With the base and cabinet made, the next step in the crafting of the CD case is to begin making the top. This piece is made from maple plywood and is framed with walnut trim (figure ) to visually match the base. The process begins with cutting some angles in walnut stock at the table saw. Later, the door will be cut to shape and added to finish off the cabinet. Materials: Maple and black-walnut stock
Table saw
Band saw
Tapering jig
Biscuit joiner; wood biscuits
Hand router
Yellow wood-glue
Clamps
Chalk or carpenter's pencil
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 power-tools, saws, drills, routers, etc. Cabinet Top Steps: - To match the angles of the base, the blade on the table saw is again set to 15 degrees, and cuts are made on the sides of the stock (figure B). A square-toothed ripping blade works best for this process.
- Next, a rabbet is cut along the inside edge (figure C) to create a lip on which the maple panel will sit.
- With the miter gauge set to 45 degrees, the ends of the stock are cut to length (figure D).
- Once cut, the top pieces are joined with biscuit joinery. For the top elements, a single #10 biscuit is sufficient (figure E).
- With the joinery slots cut, gluing up of the top can begin. During glue-up, angled shims are fastened with double-stick tape to the top pieces -- just as with the base pieces -- to provide good clamping pressure on the corner joints.
- The glued pieces are assembled and clamped together (figure F). With the flat surfaces provided by the angled shims, the clamps can get a good grip, ensuring tight corners.
- While the assembly dries, the maple panel is cut to size on the table saw (figure G).
- When the walnut frame is ready, glue is applied to the rabbet (figure H). and the maple panel is dropped into place (figure I).
Cabinet Door While the glue on the top is drying, work can begin on the final part of the case -- the hinged door. Steps: - A piece of maple plywood is cut to size for the cabinet door (figure J).
- Because the piece of walnut trim adjacent to the door edge is tapered, the door must be cut with a matching taper. Using a scribed pencil-mark as a guide, the door is cut to width on the table saw using a tapering jig (figure K). The jig holds the stock in the proper position as the door is cut with the proper taper to match the taper on the corner trim.
- The door is next cut to length, making sure to take an extra 1/8 inch off the top and bottom so the piece can be capped with maple trim.
- Solid brass hinges are used to mount the door to the cabinet. To make sure that the hinges sit flush, mortises are cut using a plunge-router (figure L). A two-flute carbide router bit is used to cut the mortises in the cabinet.
- After the mortises has been cut, a hand chisel is used to clean up the corners (figure M) and make sure they hinges will fit snugly.
- The same process is used to cut mortises in the door.
- The hinges attach to the door and cabinet with screws (figure N).
- To dial in the exact fit for the door, a scraper is used to make a few passes over the leading edge of the door (figure O).
- With the door-fit secure, the assembled top can be mounted on the case (figure P).
The final segment features final assembly and application of 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
Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
Author: Editors of Fine Woodworking magazine
Publisher: Taunton Press
ISBN: 1561583456
Mastering Woodworking Machines (Fine Woodworking Book)
Author: Mark Duginske
Publisher: Taunton Press
ISBN: 0942391985
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
The Complete Woodworker's Companion
Author: Roger Holmes
Publisher: Watson-Guptill
ISBN: 0823008665
The Complete Book of Wood Joinery
Author: Robert J. Decristoforo
Publisher: Sterling Publishing Co.
ISBN: 0806999500
Advanced Woodworking
Model: 0783539126
Author: Editors of Time Life Books
1998
Time-Life Books Inc.
Website: www.timelife.com
Popular Woodworking
F & W Publications, Inc.
Website: www.popularwoodworking.com
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