By Chris HillMore in Kitchen
Butcher block is available from many sources, and it can often be reclaimed from other projects, such as countertops. Check local consignment shops or salvage outlets for bits of butcher block. You might even try a cabinet shop to see if they have remnants left over.
Finished dimensions: 35 1/2" high x 29" wide x 20" deep
legs (4) – 1-1/2 x 1-1/2 x 34
side rails (4) – 3/4 x 2-1/2 x 23
end rails (4) – 3/4 x 2-1/2 x 14
stiles (8) – 3/4 x 2-1/2 x 27-1/2
bottom (1) – 3/4 x 14 x 23
top (1) – 1-1/2 x 20 x 29
door rails (2) – 3/4 x 1-1/2 x 17-1/4
door stiles (2) – 3/4 x 1-1/2 x 24-1/8
trash can shelf rails (2) – 3/4 x 1-1/2 x 12
trash can shelf stile (2) – 3/4 x 1-1/2 x 15-1/2
trash can shelf (1) – 3/4 x 17 x 12
stop (1) – 3/4 x 2-1/2 x 3
hinge blocks (2) – 3/4 x 1-1/2 x 2-1/2
Use Images 1, 2 and 3 as guides for drilling pocket holes in the side rails, end rails and stiles. Drill the vertical pocket holes in all of the stiles, but only in two of the side rails and two of the end rails.
Position two stiles flush with the ends of one set of side rails as shown in Image 4 and attach using glue and 1-1/4-inch pocket-hole screws. Create two assemblies. Make sure each set has only one of the side rails with the vertical pocket holes and that the pocket holes are positioned pointed away from the assembly. Be sure to position the stiles so that the vertical pocket holes also are pointed away from the assembly.
Use 3/4-inch stock as spacers for this next step. Position the end of a side rail assembly with the vertical pocket holes flush with the ends of two legs as shown in Images 1 and 2 (place the 3/4-inch spacers underneath the side rail assembly) and attach using glue and 1-1/4-inch pocket-hole screws. Drive the screws through the side rails and stiles and into the legs. Create two assemblies.
Position the end of the end rail assemblies with the vertical pocket holes flush against the end of one of the side rail/leg assemblies (Image 3) (using the 3/4-inch spacers) and attach using glue and 1-1/4-inch pocket-hole screws. Drive the screws through the end rails and stiles and into the legs.
Position the other side rail/leg assembly (Image 4) (using the 3/4-inch spacers) and attach using glue and 1-1/4-inch pocket-hole screws.
Use the layout in Image 5 as a guide for cutting the bottom to size and drilling pocket holes.
Position the bottom flush with the bottom rails and attach using glue and 1-1/4-inch pocket-hole screws (Image 6).
Use a crosscut sled and a table saw to cut the top from the butcher block. Apply the desired number of coats of polyurethane.
Position this assembly centered on the top (1 1/2 inches from the end and side) as shown in Image 1, and attach using 1-1/4-inch pocket-hole screws only. Drive the screws through the vertical pocket holes in the rails.
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