tag:blogger.com,1999:blog-50476356593843774812024-03-13T17:34:45.212-07:00Workshop ProjectsFree plans covered by Creative Commonsrinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.comBlogger18125tag:blogger.com,1999:blog-5047635659384377481.post-86570543722079413742012-10-30T10:41:00.000-07:002012-10-30T10:59:50.647-07:00Simple Sturdy Assembly BenchFor some years I have been using a small Sears Craftsman bench for woodworking assembly. Recently, I started working with a local group which was in the process of creating a MakerSpace. One item that this operation will require is a number of general purpose sturdy, inexpensive benches. As a prototype bench, I designed and constructed the largest assembly bench that my shop could accommodate. The bench has a 24" by 48" by 33" base with a 54" by 30" surface, 1 1/2" thick. The base is constructed of 2x4's and the surface, MDF.<br />
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The construction of the base started with the H shaped end sections, shown below. The section is assembled with Kreg screws and wood glue. The bottom cross piece is placed 4" from the bottom of the leg. During assembly, check squareness using a carpenters square since the 2x4's are knotty. If not square, loosen screws slightly and adjust. Don't worry about a weak joint, since there will be overlap at all joints which will more than strengthen the joint.<br />
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<tr><td class="tr-caption" style="text-align: center;">Base H section</td></tr>
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The next step is to attach the cross pieces between the H sections. Once again use the carpenters square to square up the pieces. This is important since once the base skeleton is assembled squaring will be too late.<br />
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<tr><td class="tr-caption" style="text-align: center;">Attaching cross members</td></tr>
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Use glue and Kreg screws for the joints.<br />
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<tr><td class="tr-caption" style="text-align: center;">Base skeleton assembled</td></tr>
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Note in the above picture the addition of a second 2x4 glued to the top cross member for strength. Click the picture for a better view. Now glue additional 2x4's to all skeletal members as shown in the next picture. Note the Kreg holes drilled in the top member for fastening the top to the base. Set the Kreg for 3/4" thickness.<br />
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Shown below is the completed base. If you enlarge the picture, you can see the Kreg screw hole for attaching the top.<br />
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<tr><td class="tr-caption" style="text-align: center;">Completed base</td></tr>
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The top is constructed of 3/4" MDF with a 4 1/2" edging of MDF. A thin coat of glue was spread evenly on the MDF edge pieces and then lightly clamped. The inner pieces are scrape 3/4" plywood for attaching the top. I had HomeDepot cut the MDF to 54" by 30" with the 54" vertical cut made first. The 4 1/2" edge pieces were cut on my table saw and then cut to length with the miter saw.<br />
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<tr><td class="tr-caption" style="text-align: center;">Bottom of bench top.</td></tr>
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Using a 1/8" round-over bit, all edges were dressed and sanded. The top was then sealed with SealCoat. Three layers of oil based polyurethane were then applied and sanded between coats.<br />
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<tr><td class="tr-caption" style="text-align: center;">Completed bench.</td></tr>
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<br />rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com2tag:blogger.com,1999:blog-5047635659384377481.post-1176629697158369072012-04-21T17:40:00.002-07:002012-05-01T23:16:03.011-07:00File Cabinet for Hanging FoldersMy shop tool manuals and other shop information are currently kept in a plastic desk top file case, a bench top space waster, so it's time to make a two drawer file cabinet that will fit under the bench like the multi-drawer cabinet shown in a separate post. The first order of business is to design and build a drawer that will fit in the space and work. The drawer will be build using 12mm Blonde plywood from Lowes and assembled with pocket screrws and glue. Hanging folders normally hangs from two metal strips in a file cabinet and for this we will use aluminum angle.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaE3tLJwwQrrBeVhJR2XyJryVjYQ6u50H0qB-PWzGiMsN4knzK-l9K5ICb3W_LWM2QWm8PcqGWuHGmo3ZIQmWMB5qDaaDf7lMhlDqeKmz7FrW48Zl5AFzqapU5xlTDL7qqrmWTB21wEuQ/s1600/IMG_0330C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgaE3tLJwwQrrBeVhJR2XyJryVjYQ6u50H0qB-PWzGiMsN4knzK-l9K5ICb3W_LWM2QWm8PcqGWuHGmo3ZIQmWMB5qDaaDf7lMhlDqeKmz7FrW48Zl5AFzqapU5xlTDL7qqrmWTB21wEuQ/s320/IMG_0330C.jpg" width="236" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Completed File Cabinet</td></tr>
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<tr><td class="tr-caption" style="text-align: center;">Shop files in place.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKaH5ckaM1MsTF9IixjV5_j7Ude2iywVdohqf0DWI6rw8EYZ3IGzlf0KBGE16a0NHyQieTpmRIgXUNzFa4amJabZQk2-wXMPikcewGI_ovS-d8KfaoF8sDs2LgRD0toV573cyRd_H3XqY/s1600/IMG_0307C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="255" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiKaH5ckaM1MsTF9IixjV5_j7Ude2iywVdohqf0DWI6rw8EYZ3IGzlf0KBGE16a0NHyQieTpmRIgXUNzFa4amJabZQk2-wXMPikcewGI_ovS-d8KfaoF8sDs2LgRD0toV573cyRd_H3XqY/s320/IMG_0307C.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Hanging file folder drawer prototype.</td></tr>
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The protoype drawer seems to do the job with the height adequate for tab clearance Here is the material list for the drawer. The pocket holes at the top were a mistake.<br />
<ol>
<li>Front/Back, 12 1/16" x 10 1/16", 2 ea, 12mm ply</li>
<li>Sides, 18" x 8 3/4", 2 ea, 12mm ply</li>
<li>Bottom, 18 x 13", 1 ea, 3/16" Ply</li>
<li>Rail, 1/2" x 1/2" x 1/16" x 3' aluminum angle</li>
</ol>
Now to build the cabinet which will be constructed similar to the others in this blog. Essentially, it will be a frameless type cabinet consisting of 4, 18mm thick sides and a 3/16" back. The front of the cabinet sides will be edged with 1/2" poplar and a step will be cut in the back edge to receive the 3/16" back panel.<br />
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Material Cuts for the Cabinet:<br />
<ol>
<li>Sides: 22 5/8" x 18 1/2", 2 ea, 18mm ply</li>
<li>Top/Bottom: 14" x 18 1/2", 2 ea, 18mm ply</li>
</ol>
The construction of the cabinet starts by drilling pocket holes in the top and bottom pieces. During assembly mount the top with the pocket holes inside the cabinet and the bottom either inside or outside. Before assembly, cut a notch into the back edge of the panels 1/2" wide and 3/16" deep using the table saw. This is done as shown below by clamping a strip of wood to the saw fence and creating an indent for the saw blade. Using the wood strip as the fence, pass all the cabinet pieces through the blade, then adjust the blade to widen the cut and make a second pass.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgB1FyCcEI6cv862XfZJ-ZpBiVCSHDpxMf3UUJNwsBePy_rW9hdcIyn3g8uvxJXayz0Q6DALe4GHTcTRc2J0_vNN88e72h0O3KTODFFIzCYbmEkDXIBunLSAfvTjjwwTuOZAQwLQqSN4Pg/s1600/IMG_0318C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="253" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgB1FyCcEI6cv862XfZJ-ZpBiVCSHDpxMf3UUJNwsBePy_rW9hdcIyn3g8uvxJXayz0Q6DALe4GHTcTRc2J0_vNN88e72h0O3KTODFFIzCYbmEkDXIBunLSAfvTjjwwTuOZAQwLQqSN4Pg/s320/IMG_0318C.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Table saw setup for cutting back edge notch.</td></tr>
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Glue and screw two pieces together at a time using squaring clamp blocks to hold the pieces square until the glue sets about 3/4 of an hour. The use of the squaring blocks are shown in other posts in this blog. When the cabinet is assembled glue and nail 1/2 poplar to the front edges. Finally, sand down all surfaces and, then, round over all edges with a 1/8R round over bit. Hand sand the finished cabinet and seal with Sealcoat. Sanded that surface when dry and finish with two coats of water based urethane.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi29Sokf4OnQ63JjCft9yNFyk7IHm7jLvNqzDPDkylCzCEnrqmNgSwhIzGHcGe0LcqWPRNkxBsphVkPDXO4o5pVXdH7H4lqMv8GItazZMRXW8zLTt29ceh0KCA9WrFvndljNPewBPkg1Ok/s1600/IMG_0324C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi29Sokf4OnQ63JjCft9yNFyk7IHm7jLvNqzDPDkylCzCEnrqmNgSwhIzGHcGe0LcqWPRNkxBsphVkPDXO4o5pVXdH7H4lqMv8GItazZMRXW8zLTt29ceh0KCA9WrFvndljNPewBPkg1Ok/s320/IMG_0324C.jpg" width="219" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Finished cabinet with slides mounted.</td></tr>
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Mount two pair of ball bearing slides at 7 1/4" and 17 1/8" from the top. Mount the slide on the drawer 7" from the top ( measure from top of the back or front).. For uniformity I always measure from the top of the draw.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMdbRCu6uBTOVSzwCr1H98phWb-c8xxmaHicdOFyXBuGaQzEGrm3risYBvw7RpmWgQPhf7tQNfNJy8fFW3WTbftdswyBvtTV2e7LL6BH8Plebs9jzySi-aK16KLT2KJdRkFoTReJs0eGA/s1600/IMG_0328C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="245" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMdbRCu6uBTOVSzwCr1H98phWb-c8xxmaHicdOFyXBuGaQzEGrm3risYBvw7RpmWgQPhf7tQNfNJy8fFW3WTbftdswyBvtTV2e7LL6BH8Plebs9jzySi-aK16KLT2KJdRkFoTReJs0eGA/s320/IMG_0328C.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawer with slide mounted.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWF-hnwq9fmQ00fB0-wjkM5TuNYv-_DohpmzD9N_d_MjNXGM10LW1CQ_FxGswC59ik9wgO5AKOlDRrObhG6j3_GvprVbg8Q8hTSL9jg3hJruX70woHbhRk_Ft_jrg2Lz_2Do75SljD4S0/s1600/IMG_0323C.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWF-hnwq9fmQ00fB0-wjkM5TuNYv-_DohpmzD9N_d_MjNXGM10LW1CQ_FxGswC59ik9wgO5AKOlDRrObhG6j3_GvprVbg8Q8hTSL9jg3hJruX70woHbhRk_Ft_jrg2Lz_2Do75SljD4S0/s320/IMG_0323C.jpg" width="274" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back added.</td></tr>
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To simplify moving the cabinet, two 1 1/2" rigid caster are mounted at the back of the cabinet and 2" feet made from 1 1/2" square poplar at the front. #14, 2 1/2" metal screws are used to attach the feet having pre-drilled thru with 1/4" drill and counter sunk, 1/4" deep, with 3/8 Forstner bit.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQCoXwkrhBwxgbAQlb01WTtOTO41Dk_uQjfDb69pQ61fbHahrTy9McTChzdkeXmJeNmc4wvlppWOMcCy8MtQEqdMm55yP7c5MjACwxqhzCQSxxv1snVWWJopEwqtvDQJP_0bDfAjWqOUc/s1600/IMG_0326.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQCoXwkrhBwxgbAQlb01WTtOTO41Dk_uQjfDb69pQ61fbHahrTy9McTChzdkeXmJeNmc4wvlppWOMcCy8MtQEqdMm55yP7c5MjACwxqhzCQSxxv1snVWWJopEwqtvDQJP_0bDfAjWqOUc/s320/IMG_0326.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Bottom showing legs and rigid 1/2" casters</td></tr>
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<ol></ol>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com3tag:blogger.com,1999:blog-5047635659384377481.post-1887137052655641072012-04-08T17:27:00.009-07:002012-04-16T06:34:07.534-07:00Simple Flat Panel Cabinet Doors<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih9pNdUUIwjjXowuWwTk6svMQ_CegzxfIUuhZMzz_FUEW4Bk0i8gNhCZLS29orKnqsdJquCgKd9K9ANlzv-uvRt1xYnZ-wWji-7pHhf39g9Qx7I0XUhBDq68G3D9z9gz7H8p9ld-Hugb8/s1600/IMG_0260.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEih9pNdUUIwjjXowuWwTk6svMQ_CegzxfIUuhZMzz_FUEW4Bk0i8gNhCZLS29orKnqsdJquCgKd9K9ANlzv-uvRt1xYnZ-wWji-7pHhf39g9Qx7I0XUhBDq68G3D9z9gz7H8p9ld-Hugb8/s320/IMG_0260.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Flat Panel Shop CabinetDoors</td></tr>
</tbody></table><br />
Most of my shop cabinets have been finished and now it is time to make doors. As with the other shop projects in this blog, Kreg pocket screws will be used. The method used is very similar to making cabinet frames as shown on the Kreg website. The process is to cut 2 1/4" rails and stiles from 3/4" poplar plank and then, using the table saw, cut a 0.22" groove length wise on one edge of the stile and rail.<br />
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Step by Step:<br />
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<ol><li>Cut poplar plank into 2 1/4" widths for stiles and rails</li>
<li>Cut stiles and rails roughly to length</li>
<li>Cut a 1/4" deep by 0.22" groove in one edge of the stiles and rails</li>
<li>Cut stiles to exact length</li>
<li>Clamp stiles on bench to exact door width and measure rail length</li>
<li>Cut rails to length</li>
<li>Use Kreg fixture to drill pocket holes in rails</li>
<li>Assemble one rail onto stiles as shown. Use glue and screws.</li>
<li>Clamp other rail in place and round over front inner edge</li>
<li>Cut and insert flat panel</li>
<li>Attach other rail</li>
<li>Sand all surfaces</li>
<li>Round over all outer edges</li>
<li>Drill holes for hinges</li>
<li>Hand sand door and use Sealcoat</li>
<li>Add two coats of water based urethane</li>
<li>Mount hinges on door and cabinet</li>
<li>Mount door </li>
</ol>Notes:<br />
<div><ol><li>Cutting groove: Position tables saw blade and fence, so that when a stile is run through blade in both direction ( flip the stile around ), the groove is cut to correct width and depth. You will need wood scrapes.</li>
</ol><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDh_zKSqT5zw7at_sA5Z6GV5Au6BjeuTdRHYjoTvYjxx-itC7qENhWlbH1QnkRLrspLZjZaaDH2YlV5TnPoKqyBMWzGow96K9Ind8n0qqB0_YWovLdu8uVMKqIM_PgwFeAybMjpEZPQ7A/s1600/IMG_0258.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDh_zKSqT5zw7at_sA5Z6GV5Au6BjeuTdRHYjoTvYjxx-itC7qENhWlbH1QnkRLrspLZjZaaDH2YlV5TnPoKqyBMWzGow96K9Ind8n0qqB0_YWovLdu8uVMKqIM_PgwFeAybMjpEZPQ7A/s320/IMG_0258.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Table saw set up to cut groove.</td></tr>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWZmbnToy42H2toaLUtGnt5jj8Vm_DZwE9UcR26ciRAEwaaYVKgwmYG0EhQ2plo2Uy-iq2Vm4h07C020LEjb-Fh-cx_V9MLovRncmRB2v85BVl_MG_lUmL33zlEhIaV0vFB5xFZgvYxO8/s1600/IMG_0263.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWZmbnToy42H2toaLUtGnt5jj8Vm_DZwE9UcR26ciRAEwaaYVKgwmYG0EhQ2plo2Uy-iq2Vm4h07C020LEjb-Fh-cx_V9MLovRncmRB2v85BVl_MG_lUmL33zlEhIaV0vFB5xFZgvYxO8/s320/IMG_0263.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Stiles clamped to bench to measure rail length.</td></tr>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfFVegklObaAMc-xPS8biedR-GSUlRUdhqJwcn5Bms_2jitUDIa-sqHFGTs90MHr0blj139lLHKEZPZFhqpsswSOiJN8Yd6wJuHdf50TFV8Ix1NkFHlsbd8w5OgOUC4SMKTnV43qlaUr4/s1600/IMG_0286.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfFVegklObaAMc-xPS8biedR-GSUlRUdhqJwcn5Bms_2jitUDIa-sqHFGTs90MHr0blj139lLHKEZPZFhqpsswSOiJN8Yd6wJuHdf50TFV8Ix1NkFHlsbd8w5OgOUC4SMKTnV43qlaUr4/s320/IMG_0286.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Attaching bottom rail.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtgbRspxo5iDpIsJKp2cFXjjv9bwsNVMyKzVOiPAb9FC6Ldhjfaren6FZTtQZejnJG7Q-DWMOCw3pJhxxMshTTCFoKuP-XNqQXpRVgpkwY61lSeTAVryLeYKrYkXptNDXjWQ7v0SjBtoA/s1600/IMG_0289.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjtgbRspxo5iDpIsJKp2cFXjjv9bwsNVMyKzVOiPAb9FC6Ldhjfaren6FZTtQZejnJG7Q-DWMOCw3pJhxxMshTTCFoKuP-XNqQXpRVgpkwY61lSeTAVryLeYKrYkXptNDXjWQ7v0SjBtoA/s320/IMG_0289.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Rounding over front inside edge with top rail clamped in place.</td></tr>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRgtsTxuPx6NEJdLuPjoUVrGRJZePr8emhTYQsUUfCc04C6ZHKdCu5gVtaRIX_3ivv9RINwrvfidHtqcyUP0sGf8jJXbYK9c_H3443lHEPzKR9a7nGfDK2yMifRpdpgOtcyBUAtPh3k5o/s1600/IMG_0291.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgRgtsTxuPx6NEJdLuPjoUVrGRJZePr8emhTYQsUUfCc04C6ZHKdCu5gVtaRIX_3ivv9RINwrvfidHtqcyUP0sGf8jJXbYK9c_H3443lHEPzKR9a7nGfDK2yMifRpdpgOtcyBUAtPh3k5o/s320/IMG_0291.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Inserting flat panel.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3XqvwPyIVU5QMgq995zVodOboi2GnRM0mi0zABE5PdrlRTAPC156qEEKZE6uQcmKAgsY9y1mkSKnfITkoFLI2vCchTpM5KkEOAp37-YJgNVtWxDN80JWRa_a2AZ7S01yALfB60c_8QZM/s1600/IMG_0292.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3XqvwPyIVU5QMgq995zVodOboi2GnRM0mi0zABE5PdrlRTAPC156qEEKZE6uQcmKAgsY9y1mkSKnfITkoFLI2vCchTpM5KkEOAp37-YJgNVtWxDN80JWRa_a2AZ7S01yALfB60c_8QZM/s320/IMG_0292.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Attaching top rail.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHiqdFYR5y_AulDVG1j1_8ZFK6tHCV0YijHaRYGG10-XHJN5H-uhhIHt29oSKTej6ETx-DMgVKIuFz76TxsRAFxIU_ns8frl_HPgsox_w9RYcQIiuhWRCtqDBcqsxATv9iFoNKI09Oei0/s1600/IMG_0294.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjHiqdFYR5y_AulDVG1j1_8ZFK6tHCV0YijHaRYGG10-XHJN5H-uhhIHt29oSKTej6ETx-DMgVKIuFz76TxsRAFxIU_ns8frl_HPgsox_w9RYcQIiuhWRCtqDBcqsxATv9iFoNKI09Oei0/s320/IMG_0294.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Round over outside edge.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEezIUs2r64F1eXdZD1SzjO1SfHZGd0wVHdJ3c4LdSxdu7zQkLcGa4H8NHizFz9nZO8WfuiDXBfsWhGFSD-QH2CZJqvt8ITajzPXbUpLpslwJapopuhBqs1JWjkKY_QHWZ98cBFcWkZfc/s1600/IMG_0295.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEezIUs2r64F1eXdZD1SzjO1SfHZGd0wVHdJ3c4LdSxdu7zQkLcGa4H8NHizFz9nZO8WfuiDXBfsWhGFSD-QH2CZJqvt8ITajzPXbUpLpslwJapopuhBqs1JWjkKY_QHWZ98cBFcWkZfc/s320/IMG_0295.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Locate hinges with centering scale 11" from center, i.e., 22" separation.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXD9a6qc7CO2QNrh2hrQ2LDhl1JJSlXNZiRUFwB8Vvz2ewWXR52_HJMC3rno9AwVYm5pjsyDNxi0TALha-4627SxUf-q3NG08LC628QtiszxHqXqoJDtzDYaIVKxMOruI9huYHU428Zes/s1600/IMG_0267.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXD9a6qc7CO2QNrh2hrQ2LDhl1JJSlXNZiRUFwB8Vvz2ewWXR52_HJMC3rno9AwVYm5pjsyDNxi0TALha-4627SxUf-q3NG08LC628QtiszxHqXqoJDtzDYaIVKxMOruI9huYHU428Zes/s320/IMG_0267.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">35mm Forstner bit positioning jig. </td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPj2SrtTFyCp2m8AvaDr_Y1IN8IjheSNERRO42-LaaVi5Jb5WJubHfeYLckmDP15FnqJdzqg57jvP19I11R3v4XfBP9I6hbiTdjWq9iDUySg4nivsJfDx2xpGaYoI0sRceBLrfoZ3SxLs/s1600/IMG_0297.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPj2SrtTFyCp2m8AvaDr_Y1IN8IjheSNERRO42-LaaVi5Jb5WJubHfeYLckmDP15FnqJdzqg57jvP19I11R3v4XfBP9I6hbiTdjWq9iDUySg4nivsJfDx2xpGaYoI0sRceBLrfoZ3SxLs/s320/IMG_0297.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drilling hinge hole using drill press table with fence.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxsTTgD3bZls3pH3MvocPFveMWJaRvL-lvGfZZmSKPH7YHnY4JkQMM_3OY47Bnm9VkwAaPEAhl_W0WSBKAjBWvmQuoX95ijW1yFH-9BkfPiiZI70dHc4tFhxBYZqm7zwRA0-R-wNjVnc/s1600/IMG_0276.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcxsTTgD3bZls3pH3MvocPFveMWJaRvL-lvGfZZmSKPH7YHnY4JkQMM_3OY47Bnm9VkwAaPEAhl_W0WSBKAjBWvmQuoX95ijW1yFH-9BkfPiiZI70dHc4tFhxBYZqm7zwRA0-R-wNjVnc/s320/IMG_0276.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Using jig to drill hinge mounting holes.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrAvt1AZ9c4iAjM2YzfzeB6eHLyFtv3VgFn9mwXduXRvLIkc6D7FKOuISPfNN9a8bc8ffrXBsxWnnAprhkH45dPo6nSR7K7JSab1cKuE_YdyiVIZVyY8sckBA75rj27WEP02f6TdSZyx0/s1600/IMG_0279.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrAvt1AZ9c4iAjM2YzfzeB6eHLyFtv3VgFn9mwXduXRvLIkc6D7FKOuISPfNN9a8bc8ffrXBsxWnnAprhkH45dPo6nSR7K7JSab1cKuE_YdyiVIZVyY8sckBA75rj27WEP02f6TdSZyx0/s320/IMG_0279.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Hinge mounted</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQVe-bs0j9cPYCt8qg4knDKsJ6gJpgRnKJUG_vVq0o4rPkPs7go5TxmPIlMdL7ZqozeUhQMF9eudNyM6YPSs1be6GkxQdXPhwJzxy7K5bFn_zV0692yHFEmcPUMKZgvcihcKNvnSFoFYM/s1600/IMG_0280.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQVe-bs0j9cPYCt8qg4knDKsJ6gJpgRnKJUG_vVq0o4rPkPs7go5TxmPIlMdL7ZqozeUhQMF9eudNyM6YPSs1be6GkxQdXPhwJzxy7K5bFn_zV0692yHFEmcPUMKZgvcihcKNvnSFoFYM/s320/IMG_0280.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Using jig to drill cabinet hinge mounting holes.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQXWatUUZc5b01txV5Wd7a2TrVjMzBvOm7uUUCa3iaIy1zetu05eAHyuQ1TLBPx0DEjvMM-l1-MflwTXZW8lQTEymY-iTGvcZPdnt1QLsLHWUTW53ZZe5tIA5HUo1Gl-r2lsDRUICBbXM/s1600/IMG_0281.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQXWatUUZc5b01txV5Wd7a2TrVjMzBvOm7uUUCa3iaIy1zetu05eAHyuQ1TLBPx0DEjvMM-l1-MflwTXZW8lQTEymY-iTGvcZPdnt1QLsLHWUTW53ZZe5tIA5HUo1Gl-r2lsDRUICBbXM/s320/IMG_0281.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mounting door. and done.</td></tr>
</tbody></table><br />
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<div class="separator" style="clear: both; text-align: center;"></div></div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-54423085920583486402012-03-29T18:04:00.007-07:002012-04-01T20:06:23.844-07:00Mounting Router to Rousseau 3509 PlateThe router table and cabinet base are finished. I am now ready to mount a Sears 320.17542 fixed router to a Rousseau router plate. This Sears router was chosen for several reason among them are: one, it was on sale, two, 1/2" collet, three, above plate access to the lifting mechanism. The method discussed here should also work for aluminum plates.<br />
<br />
In order to mount the router, a kit from Rousseau can be purchased, but since I had a PC type guide bushing with a 1/4" hole, I chose to purchase the following items from McMaster Carr:<br />
<ol><li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">98380A556 Dowel pin 1/4"</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">91420A330 Screw flathead M5.8 25mm</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">91217A175 Cone point socket screw M5.8 12mm</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"> 2739A38 Anti vibration thru-hole countersink, 90 deg., 3/16" - 17/32"</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">2915A22 Drill point countersink 5/64" - 3/16"</span></span></li>
</ol><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Your router may use a different screw size, but equivalent items should be available at McMaster.</span></span><br />
<span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
</span></span><br />
<span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">A comment should be made before the step by step procedure. Phenolic plastic is very hard and not easy to scratch, so I tried two ways to get the set screws to mark the plate. First, I used a Bessey mini clamp, you can see them on the bench, to press the set screw into the plastic. I did this by placing the metal end of the clamp on the set screw and the handle end above the plate. Then I tightened the clamp. This worked for four of the set screws. Hitting the plate above the set screw transferred marks from the remaining two. </span></span><br />
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<span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Step by Step</span></span><br />
<ol><li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Remove plastic plate from bottom of router. </span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Change to 1/4" chuck and add 1/4" dowel pin.</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Screw cone set screws into base as shown in picture</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Place guide bushing with 1/4" hole in plate</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Position router on bench as shown, with lift lock to front</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Place plate on router face up using dowel pin to center.</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Use spring clamps to hold router base to plate</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Use one of the methods above to cause cone set screws to mark plate</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Remove plate, find marks and enhance with center punch</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Use a small drill or drill point countersink to start hole.</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Drill hole out to screw body drill size, in my case a M5.8, 13/64"</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Turn plate over and counter sink hole using a single flute or thru-hole counter sink to proper depth</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Mount plate to router with flat head screws</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Using a scribe, mark lift hole on phenolic plate</span></span></li>
<li><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;">Drill 1/4" hole in plate and slightly counter sink on top side.</span></span></li>
</ol><br />
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<div class="separator" style="clear: both; text-align: center;"></div><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUD46LekxXZ3GPSvTIrE4vLPEaNLIySU0FJi7lv9jczsC52FEJYjdqoNCMpuWwryg3XdFG02yocze2L714KQVRo4YZyFj4MSb7fUhEf8spLJQWRN5eatAjulYs2coO9Pa-zsd7RQ-4h5E/s1600/IMG_0238.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUD46LekxXZ3GPSvTIrE4vLPEaNLIySU0FJi7lv9jczsC52FEJYjdqoNCMpuWwryg3XdFG02yocze2L714KQVRo4YZyFj4MSb7fUhEf8spLJQWRN5eatAjulYs2coO9Pa-zsd7RQ-4h5E/s320/IMG_0238.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Router placed upside down on bench. Cone end set screws in place.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGjZiiblq_usSbcjiLhG3XRftLGjI69pOQDyoT-LD-QziccQfCbKKwyMwnR1X9-JiSblQIv1_W4sQcmEpB2D4vkOVZ4QVrJF-DpBaIM-CiFpzBOmQ-bZDWceGwCaSbd7AFkZlUZNKo6I/s1600/IMG_0240.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPGjZiiblq_usSbcjiLhG3XRftLGjI69pOQDyoT-LD-QziccQfCbKKwyMwnR1X9-JiSblQIv1_W4sQcmEpB2D4vkOVZ4QVrJF-DpBaIM-CiFpzBOmQ-bZDWceGwCaSbd7AFkZlUZNKo6I/s320/IMG_0240.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Closeup of set screw.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXnTpxW8SR_15tun46-uQJ2qnNgY7qS8vQi-DmnATVHyKN9bSknaBP93ooujHqNif5WROSzHQnCud9SZ6cetLU6GCAdb4w7rT7NLeOVpXdsPN5cmFHkF03LuHAbgh-q4dCHyBxwffjjhQ/s1600/IMG_0242.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXnTpxW8SR_15tun46-uQJ2qnNgY7qS8vQi-DmnATVHyKN9bSknaBP93ooujHqNif5WROSzHQnCud9SZ6cetLU6GCAdb4w7rT7NLeOVpXdsPN5cmFHkF03LuHAbgh-q4dCHyBxwffjjhQ/s320/IMG_0242.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Guide bushing mounted in 3509 </td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikydFrJjL3RxemaaZTLlPEu2uKd4KoGuTyEKK4DM67fXtDkMBNSBU9ENwwcrkSa5aV5W1cblYn6mUIW_oij6ztt4ysdynghJGwsAuWlzUwk4lqfzPWQiLymdIjEqEWBKx2Exk-OZCOgs8/s1600/IMG_0246.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikydFrJjL3RxemaaZTLlPEu2uKd4KoGuTyEKK4DM67fXtDkMBNSBU9ENwwcrkSa5aV5W1cblYn6mUIW_oij6ztt4ysdynghJGwsAuWlzUwk4lqfzPWQiLymdIjEqEWBKx2Exk-OZCOgs8/s320/IMG_0246.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Plate positioned on router. Note 1/4" dowel and guide bushing.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQyCyhjH5QMmOzFU45ksUzbKHT5QD95iKTku7zrGzdKayvUk3wWIzgYOF9M4-gCtAHqRSztbz45FjtlHyEhdWhV_SpWswXFja39kkmasKQDExKLQ4isEfx32WEZ7wh0W1_8mEfuTghuvc/s1600/IMG_0248.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQyCyhjH5QMmOzFU45ksUzbKHT5QD95iKTku7zrGzdKayvUk3wWIzgYOF9M4-gCtAHqRSztbz45FjtlHyEhdWhV_SpWswXFja39kkmasKQDExKLQ4isEfx32WEZ7wh0W1_8mEfuTghuvc/s320/IMG_0248.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drill point countersink in drill press chuck.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgogMJrdgh785qYnjqJZUJEijcb_ifeEpGx0I4OFW25hjOq_DYt0YoxqbFBNX5_ILijilRwbzRm_2JiVrWCbHCNl9CvStrOFrjerTtelOm28QTKY4IPJRmX4Ge5yLmG3VWM_r1o8uB1wU4/s1600/IMG_0254.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgogMJrdgh785qYnjqJZUJEijcb_ifeEpGx0I4OFW25hjOq_DYt0YoxqbFBNX5_ILijilRwbzRm_2JiVrWCbHCNl9CvStrOFrjerTtelOm28QTKY4IPJRmX4Ge5yLmG3VWM_r1o8uB1wU4/s320/IMG_0254.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Router with plate mounted.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA_xCUxs4wxdCQmXck2c0DmDlpyFKSlOrpMtev4QwHFVSsQCflMQ1HdONXRolN5b-a711hLY5CilRrrx_8ckgCvbN8tmw37c6RGXpCPtinCRK7B3QbL5BWnllwV_34UjWKEpcxXO6-J4Y/s1600/IMG_0255.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgA_xCUxs4wxdCQmXck2c0DmDlpyFKSlOrpMtev4QwHFVSsQCflMQ1HdONXRolN5b-a711hLY5CilRrrx_8ckgCvbN8tmw37c6RGXpCPtinCRK7B3QbL5BWnllwV_34UjWKEpcxXO6-J4Y/s320/IMG_0255.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Flat head screws in place. Note lifter access hole at front.</td></tr>
</tbody></table><span style="color: #333333; font-family: Arial, Helvetica, sans-serif;"><span style="font-size: 12px;"><br />
</span></span>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com2tag:blogger.com,1999:blog-5047635659384377481.post-19659084314571635582012-03-01T13:25:00.022-08:002012-03-15T20:20:21.525-07:00Router Table BaseThis project describes the construction of a router table base cabinet. The construction of the <a href="http://workshopprojects.blogspot.com/2011_09_01_archive.html">Router table top.</a> is shown on a separate post in this blog.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWneFRemLMFd6k7KDnr13ifXmcVoIDG2x88OwEZ1VE4pgR9cuH2KUujPMdc4ri_nh9_I_zINdXkd1dSPZ8YCBvA58h2d2lgVSVXkYsUx6AEglTV7sTRouNsEt1ijj6qQwEtyR-5kkzSss/s1600/scan0002X.tif" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhWneFRemLMFd6k7KDnr13ifXmcVoIDG2x88OwEZ1VE4pgR9cuH2KUujPMdc4ri_nh9_I_zINdXkd1dSPZ8YCBvA58h2d2lgVSVXkYsUx6AEglTV7sTRouNsEt1ijj6qQwEtyR-5kkzSss/s320/scan0002X.tif" width="305" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Router table base, sketch from notebook.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY3-YkJJw6zRXtxXlzA7gwItFxFHGVxMgSXvaIudRczD_9FZSkuuZ5zC4ADKJjl0Rg6cEbftysmaMTPm4X3QqQiFHs11AzAO6DERIQXtaYi9H9S9mvFyTA4BsLhM2-FN8xdueso3BVBGE/s1600/IMG_0198.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiY3-YkJJw6zRXtxXlzA7gwItFxFHGVxMgSXvaIudRczD_9FZSkuuZ5zC4ADKJjl0Rg6cEbftysmaMTPm4X3QqQiFHs11AzAO6DERIQXtaYi9H9S9mvFyTA4BsLhM2-FN8xdueso3BVBGE/s320/IMG_0198.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Almost completed router table base cabinet.</td></tr>
</tbody></table><br />
<br />
This sketch of the router table base is from a 8" by 5" Top Flight notebook which I use to track my project. As you can see, this design is like many that can be found on the Web, but you will find here a complete BOM and a step by step assembly in words and pictures.<br />
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The router table base is built with Kreg pocket screws, as many of the other projects in this blog. One lesson I have learned using the pocket screws is not to assume that two pieces of square cut wood assembled at right angles will be at right angle when the glue set. After the pieces are assembled, I use squaring blocks, as shown in the pictures below, to hold the pieces square until the glue sets, about an hour.<br />
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<b>Step by Step Construction</b><br />
<div><ol></ol><div><ol><li>Make long cuts for sides, center and bottom panels 1/4" oversize, then trim to size</li>
<li>Use a table saw sled to cut ends to length. A sled is a handy tool.</li>
<li>Drill pocket holes in bottom and center panels on bottom.</li>
<li>Screw and glue pieces together. Use squaring blocks while glue is setting.</li>
<li>Drill pocket holes in drawer area verticals on inside of drawer area.</li>
<li>Glue in place and use squaring blocks.</li>
<li>Cut top cleats to size and drill pocket holes</li>
<li>Screw and glue cleats in place to end panels and drawer verticals. Make sure drawer area width is equal top to bottom.</li>
<li>Cut back support cleat to size and install under center panel. Glue.</li>
<li>Cut 1/2" poplar to 3/4" width</li>
<li>Glue and nail poplar to front edge of cabinet. Use 3/4" brads. </li>
<li>Sand cabinet, including front edge</li>
<li>Round over all cabinet edges using a router and 1/8" round over bit</li>
<li>Sand all edges lightly</li>
<li>Seal all surfaces with Bulls Eye SealCoat</li>
<li>Add back later.</li>
</ol></div></div><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX60yxJP_bvdDvAqVg8Uy5uFKtP4q6nRh5ZCUScuJwdEErWGEBfRpx-y1QkMD_AYN_b9vBMp4V259KdUfQaIFBDamVFJ7nNr9mGcoOdEd8VeFE4eeTQQWSArWZcGeQkwVF2wQrBz3G94M/s1600/IMG_0144.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgX60yxJP_bvdDvAqVg8Uy5uFKtP4q6nRh5ZCUScuJwdEErWGEBfRpx-y1QkMD_AYN_b9vBMp4V259KdUfQaIFBDamVFJ7nNr9mGcoOdEd8VeFE4eeTQQWSArWZcGeQkwVF2wQrBz3G94M/s320/IMG_0144.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Bottom screwed to side with squaring blocks.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNfjLl9MHq6r2cPUHnuQr8Msj2wv1yif-y2Zubzg-4JNg7mjywvDO3tKmw9Tf5FlWd3BTx8TMJyeHNk0NaqDTdG3dLyWfIkejiatTb4YETTWUMVhJJ12V2iLEBNGBHSZgSB-nnFUsLWl8/s1600/IMG_0145.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNfjLl9MHq6r2cPUHnuQr8Msj2wv1yif-y2Zubzg-4JNg7mjywvDO3tKmw9Tf5FlWd3BTx8TMJyeHNk0NaqDTdG3dLyWfIkejiatTb4YETTWUMVhJJ12V2iLEBNGBHSZgSB-nnFUsLWl8/s320/IMG_0145.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Main components of base assembled.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJkNsCMVn8SP0LWy_p1XaJ66awQ9jiaYVLLiSnwgBSPV03Yi0iPDk7DcqgE3-XTWYBK7xqK4vvsmb1TDfs6T2pRaiG0_qMNb8xFGd2EDl_Ndhhz9WatGHYdRqP_t37lOY0AyJc9g6Gh6I/s1600/IMG_0148.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJkNsCMVn8SP0LWy_p1XaJ66awQ9jiaYVLLiSnwgBSPV03Yi0iPDk7DcqgE3-XTWYBK7xqK4vvsmb1TDfs6T2pRaiG0_qMNb8xFGd2EDl_Ndhhz9WatGHYdRqP_t37lOY0AyJc9g6Gh6I/s320/IMG_0148.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back cleat to re-enforce center shelf.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVW3BJGfMr5woM4asftiIbSgjtBBl7G0zBGkWJgR2na-Ch80Dkv_xdAFhB0qrS6MTAv44QZS0pLyZjXAFCqJPSYGMOzSxibnPxgzAWUYL1nHgsbRRQ-6_ED-Kz6HC3XZInqzm4gd1HXLc/s1600/IMG_0147.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVW3BJGfMr5woM4asftiIbSgjtBBl7G0zBGkWJgR2na-Ch80Dkv_xdAFhB0qrS6MTAv44QZS0pLyZjXAFCqJPSYGMOzSxibnPxgzAWUYL1nHgsbRRQ-6_ED-Kz6HC3XZInqzm4gd1HXLc/s320/IMG_0147.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawer section verticals. Pocket holes on inside.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs85tfchMEFrMBaSV0kPPHPQoj2vUBPPFGSoknE_yiS3dqeGJ4x7CF_xPkTMSH7NDt4QUWW4FPqjOzv5EBCPvQvcOhzdNNLDlv7dIYJyJIz61apt-QH1CF1oEuG8B8SSAcC4laxOutrmA/s1600/IMG_0152.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhs85tfchMEFrMBaSV0kPPHPQoj2vUBPPFGSoknE_yiS3dqeGJ4x7CF_xPkTMSH7NDt4QUWW4FPqjOzv5EBCPvQvcOhzdNNLDlv7dIYJyJIz61apt-QH1CF1oEuG8B8SSAcC4laxOutrmA/s320/IMG_0152.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Cabinet with 1/2" poplar front edging.</td></tr>
</tbody></table><br />
<b>BOM - Cabinet</b><br />
<ol><li>Side 29 3/4" x 21 1/2" qty 2</li>
<li>Center/bottom 28 1/2" x 21 1/2" qty 2</li>
<li>Inside verticals 11 1/4" x 21 1/2" qty 2</li>
<li>Top cleats 3" x 28 1/2" qty 2</li>
<li>Back cleat 3" x 28 1/2" qty 1</li>
<li>Corner cleats qty 2</li>
<li>Caster strips 3" x 30" qty 2</li>
</ol><br />
<b>Making Drawers:</b><br />
<br />
Before the cabinet design was completed, the drawer area vertical height was determined. Three drawer sizes were chosen, 3", 3" and 4" and spacing of 1/4" top and bottom with 3/8" between drawers. This gives the following vertical drawer height: 1/4+3+3/8+3+3/8+4+1/4 = 11 1/4".<br />
<br />
The next need is to determine the position of the 20" Euro slides in the cabinet. Because of the way the drawers are made the side mount Euro slide are easier to mount. For simplicity the slides are mounting on the center of the drawer side plus 1/8" ( Note 1). Next we must determine the position of slides in the cabinet assuming 3,3, and 4 drawer size from the top.<br />
<ol><li>3" drawer: 1/4 + 1 1/2 = 1 3/4"</li>
<li>3" drawer: 1 3/4 + 1 1/2 + 3/8 + 1 1/2 = 5 1/8"</li>
<li>4" drawer: 5 1/8 + 1 1/2 + 3/8 + 2 = 9"</li>
</ol> To facilitate the following steps, place the cabinet on its left side on the bench. So measuring from the top of the vertical space, the first slide is at 1 3/4", the second at 5 1/8" and the last at 9". Since the drawer front will be indented, i.e., flush with the cabinet sides, the slides will be set back from the front by 9/16". The slide position lines need to be drawn perpendicular to the front cabinet edge and then a line drawn indented by 9/16" parallel to the front edge. See picture below. If you are not sure of these calculations, then lay them out on a piece of paper or scrap wood, including the top and bottom of each drawer.<br />
<br />
To mount the slides, position a left side cabinet slide with the front on the 9/16" line and along the position line with the line centered in the screw holes. Using a nail or a 1/16" center punch make a starter hole centered in the first small screw hole. Press a flat head screw into the hole and screw in place. Do the same at the far end using a small hole. Two screws per slide should be sufficient. Repeat the above with the right side drawer slides.<br />
<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgknpKEoN2K0LtELgtQnmqqyPf8gxy9kAhRYtuIpdYHa5A3WvAuAqYOq3fw1FO32a9hyphenhyphenQpkAOCEvnysWAbj5xXC3mlczs1wpmRzGR38h04_lEwfpqigQMrrOoMhP16j70bQclDBDeW_sI0/s1600/IMG_0156.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgknpKEoN2K0LtELgtQnmqqyPf8gxy9kAhRYtuIpdYHa5A3WvAuAqYOq3fw1FO32a9hyphenhyphenQpkAOCEvnysWAbj5xXC3mlczs1wpmRzGR38h04_lEwfpqigQMrrOoMhP16j70bQclDBDeW_sI0/s320/IMG_0156.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawers: 3", 3" and 4"</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl0k0CUozznClXKhoq2RpnzZbjF0aRJ5KUH0oDshwjj4j2xUFvFd-_dKOqUAJrZEa4mZ9lwHKp_WWXIwoyP0WuCh0NcTYetRJHImzPID59WOcCNmR35a0wHhqiHUcV8b5AqArsZci3c7Q/s1600/IMG_0162.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl0k0CUozznClXKhoq2RpnzZbjF0aRJ5KUH0oDshwjj4j2xUFvFd-_dKOqUAJrZEa4mZ9lwHKp_WWXIwoyP0WuCh0NcTYetRJHImzPID59WOcCNmR35a0wHhqiHUcV8b5AqArsZci3c7Q/s320/IMG_0162.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Slide positioning lines.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibOD2pBGA5D_Me2-sqdj-ClCf_t2WP-cUyjCiJwDNb21zmQstxTYXu10dWktDAP6SGUtSoKz3M6Zd_KeZNLCXbYOp_ovum-UxCs4YUw_8D2pMZ6L_8gSdcWfifSUY6cJdxRfK5460cxnY/s1600/IMG_0167.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibOD2pBGA5D_Me2-sqdj-ClCf_t2WP-cUyjCiJwDNb21zmQstxTYXu10dWktDAP6SGUtSoKz3M6Zd_KeZNLCXbYOp_ovum-UxCs4YUw_8D2pMZ6L_8gSdcWfifSUY6cJdxRfK5460cxnY/s320/IMG_0167.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Left side Euro slides mounted.</td></tr>
</tbody></table>To mount a slide to a 3" drawer, measure 1 5/8" from the top of the drawer and draw a line the length of the drawer. Lay a slide, make sure you have the correct one, along the line with the front of the slide even with the drawer front. Screw it in place. Try the drawer in the top position. It should clear the top by 1/4". Repeat this process with the other drawers, except for the 4" drawer, draw the line at 2 1/8".. There should be a 3/8" clearance between drawers.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9_eauuhpr832sA-BDtfCTY52-pYAiVGq8t3HmYUIPtIhambCHUsuFnKrxI966sbs-_VY6Ue4PrZdiX_gRUvB3eXov3R44u82sUPzFRJmzOt3rQzmgX0yxxjOebN5e_8LRJnwMJmHcn1o/s1600/IMG_0169.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh9_eauuhpr832sA-BDtfCTY52-pYAiVGq8t3HmYUIPtIhambCHUsuFnKrxI966sbs-_VY6Ue4PrZdiX_gRUvB3eXov3R44u82sUPzFRJmzOt3rQzmgX0yxxjOebN5e_8LRJnwMJmHcn1o/s320/IMG_0169.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Measure 1 5/8" from top of the 3" drawer both ends.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpZxeDfpWPE9yGnVqwr_oq00HMJFJuIBzbvTfoS89sDP-bwFUicMYY76xolhyKNFdKUeueCN59OB6RVaoIZaCHVU5-RdQLzU4CAWd4xjW6RcthbI3rFho71clenrElkZv7Sbq87zt7Rds/s1600/IMG_0170.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpZxeDfpWPE9yGnVqwr_oq00HMJFJuIBzbvTfoS89sDP-bwFUicMYY76xolhyKNFdKUeueCN59OB6RVaoIZaCHVU5-RdQLzU4CAWd4xjW6RcthbI3rFho71clenrElkZv7Sbq87zt7Rds/s320/IMG_0170.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mark line on side of drawer.</td></tr>
</tbody></table><br />
<div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><b>Making the Drawer Fronts:</b></div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">The following method works for both full extension and Euro slides.</div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">Step 1: From 1/2 (12 mm) plywood cut the front 1/4" smaller than the horizontal opening and 1/4" larger than the nominal drawer height. </div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">Step 2: With a 1/8"R round over bit dress the front edge of the drawer front. After filling any voids in the edge sand and seal the drawer front both sides. Then coat with polyurethane.</div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; background-attachment: initial; background-clip: initial; background-color: white; background-image: initial; background-origin: initial; border-bottom-color: rgb(238, 238, 238); border-bottom-style: solid; border-bottom-width: 1px; border-image: initial; border-left-color: rgb(238, 238, 238); border-left-style: solid; border-left-width: 1px; border-right-color: rgb(238, 238, 238); border-right-style: solid; border-right-width: 1px; border-top-color: rgb(238, 238, 238); border-top-style: solid; border-top-width: 1px; box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; margin-left: auto; margin-right: auto; padding-bottom: 5px; padding-left: 5px; padding-right: 5px; padding-top: 5px; position: relative; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6v01RN1xvwh1EKecpmfLarsKLR-roJiWrH8ZALHs9vHHxwxTkRxUUBFQ9p68DmNLcdo7emgGuq9EMEXHWBoNJ13X3E7PxbjWCIJZxk74zwOLbMMIfXH8DT-Fwxj39jIWfSV0VU_wpE84/s1600/IMG_0182.JPG" imageanchor="1" style="color: #888888; margin-left: auto; margin-right: auto; text-decoration: none;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6v01RN1xvwh1EKecpmfLarsKLR-roJiWrH8ZALHs9vHHxwxTkRxUUBFQ9p68DmNLcdo7emgGuq9EMEXHWBoNJ13X3E7PxbjWCIJZxk74zwOLbMMIfXH8DT-Fwxj39jIWfSV0VU_wpE84/s320/IMG_0182.JPG" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; background-attachment: initial; background-clip: initial; background-color: transparent; background-image: initial; background-origin: initial; background-position: initial initial; background-repeat: initial initial; border-bottom-style: none; border-color: initial; border-color: initial; border-image: initial; border-left-style: none; border-right-style: none; border-top-style: none; border-width: initial; border-width: initial; box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; padding-bottom: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px; position: relative;" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 11px;">Drawer front marked for handle.</td></tr>
</tbody></table><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">Step 3: Find vertical and horizontal of the drawer front and mark with pencil. Using center punch, mark position of handle holes. Then drill holes using a 3/16" brad pointed or dowel bit to prevent tearing around hole. </div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; background-attachment: initial; background-clip: initial; background-color: white; background-image: initial; background-origin: initial; border-bottom-color: rgb(238, 238, 238); border-bottom-style: solid; border-bottom-width: 1px; border-image: initial; border-left-color: rgb(238, 238, 238); border-left-style: solid; border-left-width: 1px; border-right-color: rgb(238, 238, 238); border-right-style: solid; border-right-width: 1px; border-top-color: rgb(238, 238, 238); border-top-style: solid; border-top-width: 1px; box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; margin-left: auto; margin-right: auto; padding-bottom: 5px; padding-left: 5px; padding-right: 5px; padding-top: 5px; position: relative; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu4D854KMAuRFcfBgW8A8ihhas1Pp8IfjEv7vkbeNDoPkhVJd1iBK-sVGutJ4m95oQAh2cBWyc9XXhSTFUlrM7ViqUF5om7w4M6pzQuG_v_ywmTS-3L_J8EWSgpVMM9k87m-hICa6fdBE/s1600/IMG_0183.JPG" imageanchor="1" style="color: #888888; margin-left: auto; margin-right: auto; text-decoration: none;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu4D854KMAuRFcfBgW8A8ihhas1Pp8IfjEv7vkbeNDoPkhVJd1iBK-sVGutJ4m95oQAh2cBWyc9XXhSTFUlrM7ViqUF5om7w4M6pzQuG_v_ywmTS-3L_J8EWSgpVMM9k87m-hICa6fdBE/s320/IMG_0183.JPG" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; background-attachment: initial; background-clip: initial; background-color: transparent; background-image: initial; background-origin: initial; background-position: initial initial; background-repeat: initial initial; border-bottom-style: none; border-color: initial; border-color: initial; border-image: initial; border-left-style: none; border-right-style: none; border-top-style: none; border-width: initial; border-width: initial; box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; padding-bottom: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px; position: relative;" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 11px;">Front drilled for handle.</td></tr>
</tbody></table><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">Step 4: Clamp the drawer front to front part of the drawer. Use 1/8" spacers at bottom edge and center the front. Use a mini clamp to hold front in place will handle holes are drilled through. Insert handle screws from inside draw and fastened handle. If it was a wide drawer, 3/16" holes would be drilled through the front of the drawer at each end, then 3/4" #8 screws would be used to hold the drawer front in place. After that, drill and mount the handle. </div><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; background-attachment: initial; background-clip: initial; background-color: white; background-image: initial; background-origin: initial; border-bottom-color: rgb(238, 238, 238); border-bottom-style: solid; border-bottom-width: 1px; border-image: initial; border-left-color: rgb(238, 238, 238); border-left-style: solid; border-left-width: 1px; border-right-color: rgb(238, 238, 238); border-right-style: solid; border-right-width: 1px; border-top-color: rgb(238, 238, 238); border-top-style: solid; border-top-width: 1px; box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; margin-left: auto; margin-right: auto; padding-bottom: 5px; padding-left: 5px; padding-right: 5px; padding-top: 5px; position: relative; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtrX09kBpUSGIC1D1576Xqf-ago52_VfAYwz1XBFvE3D6CUrQfwxJt-mXx77okMDoQAYkGnNrT-VJ2wnJ2R6Xrl52N3lubQDliywh4Rzanm3YYqIf5-oNI8cr-R0HP-pOyLglIa_QLmgE/s1600/IMG_0185.JPG" imageanchor="1" style="color: #888888; margin-left: auto; margin-right: auto; text-decoration: none;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtrX09kBpUSGIC1D1576Xqf-ago52_VfAYwz1XBFvE3D6CUrQfwxJt-mXx77okMDoQAYkGnNrT-VJ2wnJ2R6Xrl52N3lubQDliywh4Rzanm3YYqIf5-oNI8cr-R0HP-pOyLglIa_QLmgE/s320/IMG_0185.JPG" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; background-attachment: initial; background-clip: initial; background-color: transparent; background-image: initial; background-origin: initial; background-position: initial initial; background-repeat: initial initial; border-bottom-style: none; border-color: initial; border-color: initial; border-image: initial; border-left-style: none; border-right-style: none; border-top-style: none; border-width: initial; border-width: initial; box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; padding-bottom: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px; position: relative;" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 11px;">Squeeze clamp holding drawer front in place with 1/8" spacer at bottom edge.</td></tr>
</tbody></table><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">: </div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; background-attachment: initial; background-clip: initial; background-color: white; background-image: initial; background-origin: initial; border-bottom-color: rgb(238, 238, 238); border-bottom-style: solid; border-bottom-width: 1px; border-image: initial; border-left-color: rgb(238, 238, 238); border-left-style: solid; border-left-width: 1px; border-right-color: rgb(238, 238, 238); border-right-style: solid; border-right-width: 1px; border-top-color: rgb(238, 238, 238); border-top-style: solid; border-top-width: 1px; box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; margin-left: auto; margin-right: auto; padding-bottom: 5px; padding-left: 5px; padding-right: 5px; padding-top: 5px; position: relative; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxlczTeKgPlFKpUQNXpnqdS9fYNpPORSbZYCVEKEnRzw464J5xBAVO75PPpjdVddvJWRRc4ik7mH2mS6JkUh8zxMM26FbANlAmvACSL3r6F4pjLxAhC8Vtfn1ng6drvaSLQ97dQYc3n4/s1600/IMG_0186.JPG" imageanchor="1" style="color: #888888; margin-left: auto; margin-right: auto; text-decoration: none;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxlczTeKgPlFKpUQNXpnqdS9fYNpPORSbZYCVEKEnRzw464J5xBAVO75PPpjdVddvJWRRc4ik7mH2mS6JkUh8zxMM26FbANlAmvACSL3r6F4pjLxAhC8Vtfn1ng6drvaSLQ97dQYc3n4/s320/IMG_0186.JPG" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; background-attachment: initial; background-clip: initial; background-color: transparent; background-image: initial; background-origin: initial; background-position: initial initial; background-repeat: initial initial; border-bottom-style: none; border-color: initial; border-color: initial; border-image: initial; border-left-style: none; border-right-style: none; border-top-style: none; border-width: initial; border-width: initial; box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; padding-bottom: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px; position: relative;" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 11px;">Front positioned and ready to be drilled.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; background-attachment: initial; background-clip: initial; background-color: white; background-image: initial; background-origin: initial; border-bottom-color: rgb(238, 238, 238); border-bottom-style: solid; border-bottom-width: 1px; border-image: initial; border-left-color: rgb(238, 238, 238); border-left-style: solid; border-left-width: 1px; border-right-color: rgb(238, 238, 238); border-right-style: solid; border-right-width: 1px; border-top-color: rgb(238, 238, 238); border-top-style: solid; border-top-width: 1px; box-shadow: rgba(0, 0, 0, 0.0976563) 1px 1px 5px; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; margin-left: auto; margin-right: auto; padding-bottom: 5px; padding-left: 5px; padding-right: 5px; padding-top: 5px; position: relative; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC2nGfjKTB0xYX4cqebf6T-wPu8BMVG8D-f6lXqX3B0nSv3xLrhvFqqhc3LLmEAEWiNW5tFmtd5HmA6HycaEyibl6je0Yg0JiYpCEmy9GfAA0XjHw0ndaAR4L0ef9Gj7Lpyn0rE5TpWyw/s1600/IMG_0187.JPG" imageanchor="1" style="color: #888888; margin-left: auto; margin-right: auto; text-decoration: none;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC2nGfjKTB0xYX4cqebf6T-wPu8BMVG8D-f6lXqX3B0nSv3xLrhvFqqhc3LLmEAEWiNW5tFmtd5HmA6HycaEyibl6je0Yg0JiYpCEmy9GfAA0XjHw0ndaAR4L0ef9Gj7Lpyn0rE5TpWyw/s320/IMG_0187.JPG" style="-webkit-box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; background-attachment: initial; background-clip: initial; background-color: transparent; background-image: initial; background-origin: initial; background-position: initial initial; background-repeat: initial initial; border-bottom-style: none; border-color: initial; border-color: initial; border-image: initial; border-left-style: none; border-right-style: none; border-top-style: none; border-width: initial; border-width: initial; box-shadow: rgba(0, 0, 0, 0.0976563) 0px 0px 0px; padding-bottom: 0px; padding-left: 0px; padding-right: 0px; padding-top: 0px; position: relative;" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 11px;">Finished drawer front.</td></tr>
</tbody></table><div class="separator" style="background-color: white; clear: both; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px; text-align: left;">Step 4: The method used above will not work for the top draw, so I use two small pieces of carpet tape on the front of the drawer. A spacer is used to space the drawer fronts. Set the drawer front at an angle on the spacer then tip the front forward until the tape is contacted. Clamp and drill handle holes.</div><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu88ipx2WhDGPt2xSwkqcGbZXWL8FuA6dfKFVAU2yU96JdXVi8yBwmRLkOdqn8d06L08FcR6UE2C9Uvtj3KaBGeGIzpths1i0k7OX6MnBPasJM3pT0XYPIo7gTa2zJ3K666SL5oY1SUtQ/s1600/IMG_0193.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu88ipx2WhDGPt2xSwkqcGbZXWL8FuA6dfKFVAU2yU96JdXVi8yBwmRLkOdqn8d06L08FcR6UE2C9Uvtj3KaBGeGIzpths1i0k7OX6MnBPasJM3pT0XYPIo7gTa2zJ3K666SL5oY1SUtQ/s320/IMG_0193.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Using carpet tape. Note 1/8" spacers.</td></tr>
</tbody></table><b>BOM Drawers</b><br />
<br />
3" Drawer:<br />
<ol><ol><li>Sides: qty 2, 2 13/16" x 16" x 1/2"</li>
<li>Front/Back: qty 2, 2 13/16" x 5 9/16" x 1/2"</li>
<li>Bottom: qty 1, 5 9/16" x 16" x 3/16"</li>
</ol></ol> 4" Drawer:<br />
<ol><ol><li>Sides: qty 2, 3 13/16" x 16" x 1/2"</li>
<li>Front</li>
<li>Bottom:</li>
</ol></ol> Misc:<br />
<ol><ol><li>20" Side mount Euro Slides, Liberty <span style="background-color: white; color: #333333; font-size: 14px; line-height: 17px; text-align: left;"><span style="font-family: inherit;">D66320C-W-TS</span></span><strong style="background-color: white; color: #333333; font-family: helvetica, arial, sans-serif; font-size: 14px; line-height: 17px; text-align: left;">,</strong> HD</li>
<li>Kreg 1" pocket screws</li>
<li>Glue</li>
</ol></ol><br />
<br />
Material: 12mm (15/32") Blonde Plywood from Lowes or equivalent.<br />
<ol></ol><b>Casters:</b><br />
<b><br />
</b><br />
For a small shop it is very handy to be able to move tool cabinets around. Casters have been added to most of the projects on this blog, but they all have a common failing, they move a little even if locked. The router cabinet with the router installed has a low center of gravity, so on this cabinet two rigid caster and two short legs have been used. Another choice would be to use two <a href="http://www.rockler.com/product.cfm?page=2053&site=ROCKLER">levelers</a> in place of the legs. To move the cabinet simply lift the end with the legs off the floor and roll on the caster. I would worry about using this method on cabinets with a high center of gravity like with a bench drill press because lifting one end might tip the hole thing. The method may work with the miter cabinet.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRn1WlxFVhT-KJ-AnKsFrZtFFGQ8tFkjwH_Oz4lce2-2nmG0EfGMgk4H7zqq7wrEgJD3Y1ZqSdy4lQA0dY2gpamowaSoHLnkTphOP-lAr6LINzkjmv7FrBHF0XjpKYIXwzL5zMkGGOB10/s1600/IMG_0210.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRn1WlxFVhT-KJ-AnKsFrZtFFGQ8tFkjwH_Oz4lce2-2nmG0EfGMgk4H7zqq7wrEgJD3Y1ZqSdy4lQA0dY2gpamowaSoHLnkTphOP-lAr6LINzkjmv7FrBHF0XjpKYIXwzL5zMkGGOB10/s320/IMG_0210.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Legs and 2" rigid casters<br />
<div style="text-align: left;"><br />
</div></td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQsaqF8wUdz-pRRYuqDcmR6F__9n8HXqgQVHrE4grXFrLn8ADU-2zcClwVumxG4-bF3Vur0GADhRq_MDvyBPIvRL0Bcxx-9-zYUdzkZFv9_BSnK7w488Rc089hNt6lRLqGEvdBbnl45gM/s1600/IMG_0211.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQsaqF8wUdz-pRRYuqDcmR6F__9n8HXqgQVHrE4grXFrLn8ADU-2zcClwVumxG4-bF3Vur0GADhRq_MDvyBPIvRL0Bcxx-9-zYUdzkZFv9_BSnK7w488Rc089hNt6lRLqGEvdBbnl45gM/s320/IMG_0211.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Legs cut from 1 1/2" poplar and mounted with a 5/16" x 3 1/2" lag bolt.</td></tr>
</tbody></table><br />
<b>Electric:</b><br />
<br />
The electric consists of a front mounted switch and an internal duplex outlet. The switch turns both the router and a vacuum on together. Initially, a wall type switch will be used, but will be replaced by the Grizzily switch shown below which is designed to mount on a standard electric box.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjetrQc5j3NIxDXGCXZLQ0fPa5RZ4BEIQMMTt22iPP3ubdMI2GXL85rh3Nlo24U-_m5m7ZmyYLGuTQzGSE_ldy2iELDh-lxSwCIVMD97gTFEyVTDNXWI-lJj0vTBYYG3yfsOM76r7lK7Gw/s1600/IMG_0200.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjetrQc5j3NIxDXGCXZLQ0fPa5RZ4BEIQMMTt22iPP3ubdMI2GXL85rh3Nlo24U-_m5m7ZmyYLGuTQzGSE_ldy2iELDh-lxSwCIVMD97gTFEyVTDNXWI-lJj0vTBYYG3yfsOM76r7lK7Gw/s320/IMG_0200.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Electric boxes to be mounted. Note bracket.</td></tr>
</tbody></table><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiec88z53jKDxJsnfVZihWtU0tMggnZvZ6kd8lPyqrSMdZ-jmnS7qLdE4H9uVeg3cKSL_cGB8GP0zlFTJwbjR6N1oFWBfXj6iFYMvfcLE3pOACDiYFF4mqD6VFfWbIoN1Kxx-FHbEwVz3U/s1600/IMG_0201.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiec88z53jKDxJsnfVZihWtU0tMggnZvZ6kd8lPyqrSMdZ-jmnS7qLdE4H9uVeg3cKSL_cGB8GP0zlFTJwbjR6N1oFWBfXj6iFYMvfcLE3pOACDiYFF4mqD6VFfWbIoN1Kxx-FHbEwVz3U/s320/IMG_0201.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Bracket for switch box.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5c-_27JUrgT7k-Y4LgxWomRHvLgjxtc1c_7z0Amqq7KrrQu6Kr1f1EEYyJloNA4yR_w3smrtxjqjTVdI3LqynETuRql7hv_rhYDfHznEZQ8eGS8glDMOEbJTgyEJ-rD5RFG4mMIWwg10/s1600/IMG_0205.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5c-_27JUrgT7k-Y4LgxWomRHvLgjxtc1c_7z0Amqq7KrrQu6Kr1f1EEYyJloNA4yR_w3smrtxjqjTVdI3LqynETuRql7hv_rhYDfHznEZQ8eGS8glDMOEbJTgyEJ-rD5RFG4mMIWwg10/s320/IMG_0205.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Switch mounted.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvgQWSrkp3KYGeXZ6qJrqR8oo2cSVSdWi0_H6aACFv33MX4t_uZ5w5HE4Eh2lp71sVdRfqLNdUGTek5Q3TwTl00ulXFsXdB0aWO46D7mYwxK_sECA9AKZAs35s290k0pzURZqYEXpHF1U/s1600/IMG_0208.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvgQWSrkp3KYGeXZ6qJrqR8oo2cSVSdWi0_H6aACFv33MX4t_uZ5w5HE4Eh2lp71sVdRfqLNdUGTek5Q3TwTl00ulXFsXdB0aWO46D7mYwxK_sECA9AKZAs35s290k0pzURZqYEXpHF1U/s320/IMG_0208.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Power cord dressed at back of drawer area.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBaybUuqrSJU9MBJg6Qup03Vu0gvTVDehtmURDJwvo4KKBC-B0YLr60Pg6snl5la_inImAjKXf8BaH23yzhQtLipgUrFfBsW49htCVEwjx1LTXW5VQu8Xagq9-AQBfHsB0E9xEA1WZtOw/s1600/IMG_0209.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBaybUuqrSJU9MBJg6Qup03Vu0gvTVDehtmURDJwvo4KKBC-B0YLr60Pg6snl5la_inImAjKXf8BaH23yzhQtLipgUrFfBsW49htCVEwjx1LTXW5VQu8Xagq9-AQBfHsB0E9xEA1WZtOw/s320/IMG_0209.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Duplex outlet and power cord.</td></tr>
</tbody></table><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMJXNpXSUT60bawiGRE4ukeRYzLkFpfWFxrnI_8H9RR5kGdhwdhOZA2aqNszQE8b7QZcwHKb6THof6ax5ZJjVOnsVrb0gp7PhfOMRTgjXVjHFYgNe44XzSCQ4IBMPGFCkOImPDyn-rdPo/s1600/h8241.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMJXNpXSUT60bawiGRE4ukeRYzLkFpfWFxrnI_8H9RR5kGdhwdhOZA2aqNszQE8b7QZcwHKb6THof6ax5ZJjVOnsVrb0gp7PhfOMRTgjXVjHFYgNe44XzSCQ4IBMPGFCkOImPDyn-rdPo/s320/h8241.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Switch that will mount in standard electric box as shown in above picture.</td></tr>
</tbody></table><b><br />
</b><br />
<div class="separator" style="clear: both; text-align: center;"></div><br />
<br />
<div class="separator" style="clear: both; text-align: center;"></div><br />
<br />
<ol></ol>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com1tag:blogger.com,1999:blog-5047635659384377481.post-6177433748460572922012-02-23T16:14:00.003-08:002012-03-16T16:46:05.215-07:00Multi-Drawer Home Office Cabinetrinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-90377006502335342552012-02-23T16:13:00.006-08:002012-03-16T16:47:13.414-07:00Multi Drawer Shop Cabinet<div class="separator" style="clear: both; text-align: left;">Except for my Craftman tool box, My shop had no drawers which is one reason that drawers are being added to all the shop projects. </div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwUL1g1Mwi7HELwodt0RMbYo30OPKkZGcUnqRijY6JClasw7GUoL2yWEm0KbCO2pNrQVD4g9jVUH3LlQFoN0uTaU2-hrKU0_vKs5hZ8K20IhvGgLsuXKZH-tdNT1mXMCYXCtu9mNjEv5E/s1600/IMG_0158.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwUL1g1Mwi7HELwodt0RMbYo30OPKkZGcUnqRijY6JClasw7GUoL2yWEm0KbCO2pNrQVD4g9jVUH3LlQFoN0uTaU2-hrKU0_vKs5hZ8K20IhvGgLsuXKZH-tdNT1mXMCYXCtu9mNjEv5E/s320/IMG_0158.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;"><b>BOM</b></div><div class="separator" style="clear: both; text-align: left;"></div><ol><li>Top/Bottom: qty 2, 24 1/2" x 19 1/2"</li>
<li>Sides: qty 2, 21 1/2" x 19 1/2"</li>
<li>Cleats: qty 2, 4 1/2" x 25 1/2"</li>
<li>Caster blocks: qty 4, 4" x 3"</li>
<li>Casters: 2"</li>
</ol>Drawers:<br />
<div class="separator" style="clear: both; text-align: left;"></div><ol><li>Sizes: 2", 3", 4", 4", 5"</li>
<li>Spacing Top/Bottom: 1/4"</li>
<li>Spacing between drawers: 3/8"</li>
<li>Vertical drawer space: 1/4 + 2 + 3/8 + 3 + 3/8 + 4 + 3/8 + 4 + 3/8 + 5 + 1/4 = 20"</li>
<li>Slide Positions: 1 1/4", 4 1/8", 8", 12 3/8", 17 1/4"</li>
<li>Slide type: full extension Liberty D80618C-ZP-W</li>
<li>Drawer depth/width: 18 1/2" / 23 1/2"</li>
</ol>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-34084004530109495332012-02-13T17:30:00.005-08:002012-03-19T13:46:47.757-07:00Euro Drawer Slide MountingIf a full extension slide is not required, the Euro slide at less than half the cost can be used. The discussion here assumes the use of side mounted Euro drawer slides, not bottom corner slides. Because we are using side mounts, the full extension drawer slide method can be used with two exceptions:<br />
<ol><li>On the Euro slide the screw holes in drawer part are 5/32 lower than the holes in the cabinet part where the screw holes in the full extension ball bearing slide are aligned. Check it out.</li>
<li>The Euro slides are not full extension, so the drawer depth is about 4" shorter than the slide length unless part of the drawer remaining in the cabinet is acceptable. In the picture below, the drawer is 16" deep using 18" slides.</li>
</ol> For a full discussion of drawer mounting see the post on full extension slide; however, below find pictures of drawers mounted with Euro slides. In these pictures the slide is mounted on the drawer at approximately 3/4 of nominal draw height which for the 4" drawer is 3" and 5 1/8" drawer 4". On the drawer an additional 1/8" ( 5/32") must be added to adjust for screw hole vertical alignment. The cabinet slides are at the following positions measured from the top of the opening where the drawers are 4" and 5 1/8" in height.<br />
<ol><li>Top Drawer: 1/4" + 3" = 3 1/4"</li>
<li>Second Drawer: 1/4" + 4" + 3/8" + 4" = 8 5/8"</li>
</ol>For the slide positions on the drawers:<br />
<ol><li>Top: 3 1/8" from top of drawer</li>
<li>Second: 4 1/8"</li>
</ol>where the 1/8" (5/32") compensates for the hole alignment.<br />
<br />
One more note, when mounting the slides in the cabinet, use one screw at the back and one screw in the vertical slot in the front of the slide to allow for final adjustment. When you finally get to the point of mounting the fronts to the drawers and aligning the seams around the drawers one or both of the cabinet slides may need to be moved up or down a little to even the horizontal seams.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju64IjcaobNQU8oF3DQFB5j__2SwbR5BddEN1kxYSHxHK_FXVKuJHdwWYneIDaY1MZsimZtbtZMo4fVr4VJHYOH-TQC7WSErULzb1XaxWOagCjGPKIGLSoUY9LRFGfR2VfEdrkVyZO8XY/s1600/IMG_0126.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEju64IjcaobNQU8oF3DQFB5j__2SwbR5BddEN1kxYSHxHK_FXVKuJHdwWYneIDaY1MZsimZtbtZMo4fVr4VJHYOH-TQC7WSErULzb1XaxWOagCjGPKIGLSoUY9LRFGfR2VfEdrkVyZO8XY/s320/IMG_0126.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Front view</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO8AzREavhE_IfhyhHI-z5QhYNFADGZN6j9tIOhaiXP9qQytaIyfQeu7V3Nv8A5UNGmeamStYD0xa6c_cj_ua2k7uVl3K4u1rpXD_YS6kbuWavKbQBma1OkA9Qwp86uheCcQ_wtoI7rME/s1600/IMG_0161.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO8AzREavhE_IfhyhHI-z5QhYNFADGZN6j9tIOhaiXP9qQytaIyfQeu7V3Nv8A5UNGmeamStYD0xa6c_cj_ua2k7uVl3K4u1rpXD_YS6kbuWavKbQBma1OkA9Qwp86uheCcQ_wtoI7rME/s320/IMG_0161.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">With drawer at full extension. 20" slides with 18" drawer</td></tr>
</tbody></table>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-78760780315946284612012-02-13T17:29:00.004-08:002012-04-23T08:58:45.277-07:00Simplified Drawer Construction<div class="separator" style="clear: both; text-align: center;"></div>After making several drawers for shop cabinets, the following procedure has been worked out.<br />
<br />
Procedure Steps:<br />
<ol><li>Cut sides from 1/2" plywood</li>
<li>Drill pocket holes in the front and back pieces</li>
<li>Using jig, glue and screw sides</li>
<li>Use corner blocks and clamps to square up drawer</li>
<li>Cut bottom from 3/16" plywood</li>
<li>Glue and nail to drawer bottom</li>
</ol><b>To make a 4" high drawer that is 16" deep by 22 1/2" wide</b>. This is a drawer used in the bandsaw cabinet and is mounted with 18" euro slides. These slides are not full extension, so about 2" of the drawer remains in cabinet. The plywood used for the bottom was 3/16" thick underlayment plywood sold at HD with the back of the plywood face up in the drawer. The sides were cut from 1/2" Blonde plywood from Lowes which has been pre-cut to 4 ft by 2 ft panels for easy car transport.<br />
<br />
Step by Step Drawer Construction<br />
<br />
<ol><li>Cut four side pieces 3 13/16" wide from 2 ft wide, 1/2" panel (note1)</li>
<li>Clamp two pieces together, aligning the edges</li>
<li>Use miter saw to trim one end to square (note2)</li>
<li>With straight edge, mark pieces at 16" and cut with miter saw</li>
<li>Clamp the other two pieces, repeat above steps but measure to 21 9/16" (front, rear) (note3)</li>
<li>With Kreg fixture drill front and rear with two pocket holes per end</li>
<li>Place a side piece on the bench, clamp as shown in the picture (note5)</li>
<li>Clamp jig at end of piece</li>
<li>Spread glue on front piece end, place against jig and side piece. Clamp in place. (note6)</li>
<li>Fasten with 1" Kreg screws, do not over tighten. Use drill break.</li>
<li>Repeat steps 9 and 10 for other pieces.</li>
<li>With box complete use squaring blocks and clamps to guaranty squareness.</li>
<li>Cut bottom to size and glue and nail (5/8" brads) in place.</li>
<li>Sand sides and edges, then round over with 1/8 roundover router bit </li>
<li>Finish with a good hand sanding</li>
<li>Sealcoat drawer and finish inside with polyurethane.</li>
</ol><br />
Notes:<br />
<br />
<ol><li>To cut width accurately, make table saw test cuts in 3/16 ply scrapes.</li>
<li>This Blonde plywood surface splinters easily, so take your time or place a piece of scrap wood under piece being cut.</li>
<li>Measure after cutting and make sure length is within 1/32"</li>
<li>Use the 1/2" Kreg guide block and drill</li>
<li>The front and back pieces fit between the side pieces making the drawer width 22 1/2"</li>
<li>All this clamping is necessary to keep the front piece from pulling out of place when the screws are tightened. This happens because the screws are going in at an angle and want to pull the piece out of place as the screws are turned..</li>
</ol><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJIEpXlXt-SiGS_0Ueaa-cAUldZEoo-khAkLjw9DSS1WvPFJBAAFEhfLIxv40xjxVwT1H9w42mBaLK0z6PyT78gC1127Tlw0q_f4su7ilKpQAz3vIw-blG0sGiTTXghyphenhyphenN41zHuOUUDZPU/s1600/IMG_0122.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJIEpXlXt-SiGS_0Ueaa-cAUldZEoo-khAkLjw9DSS1WvPFJBAAFEhfLIxv40xjxVwT1H9w42mBaLK0z6PyT78gC1127Tlw0q_f4su7ilKpQAz3vIw-blG0sGiTTXghyphenhyphenN41zHuOUUDZPU/s320/IMG_0122.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Kreg pocket hole jig with 1/2" guide block</td></tr>
</tbody></table><br />
<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcQjmZmByIwGBiHtgSLelFr3VwpOs8OPxReDUVMr3lWlUL4wKrGrs3U_4J1h3kCWRHmInSt2mIPZNE7NsNIJkUOawy5bBGj3kiE9lbe25_T7UEZ5apCl1gRavMy_ci_qjTNAM6-jhby0k/s1600/IMG_0124.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgcQjmZmByIwGBiHtgSLelFr3VwpOs8OPxReDUVMr3lWlUL4wKrGrs3U_4J1h3kCWRHmInSt2mIPZNE7NsNIJkUOawy5bBGj3kiE9lbe25_T7UEZ5apCl1gRavMy_ci_qjTNAM6-jhby0k/s320/IMG_0124.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Pieces clamped in place with jig ready for screws</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimdwuE6-qWWNyBB1BOzZc5b2tm2BgyOathumjbfw6_U5q2za6kOxZDoSIxs7-JD_9ZxzMbV0Mis76Gkuz2T1utYDNAwwmVL57MhqyllOcsVIAf56Iz9kTSwlGld_g-D8iR-lARj5QXiIk/s1600/IMG_0138.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimdwuE6-qWWNyBB1BOzZc5b2tm2BgyOathumjbfw6_U5q2za6kOxZDoSIxs7-JD_9ZxzMbV0Mis76Gkuz2T1utYDNAwwmVL57MhqyllOcsVIAf56Iz9kTSwlGld_g-D8iR-lARj5QXiIk/s320/IMG_0138.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Clamp jig closeup.</td></tr>
</tbody></table><div style="text-align: right;"></div><div class="separator" style="clear: both; text-align: center;"></div><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-csjs4StePjtkROlnlWU1K9VF8AW_JWrTyoDpXniNMQT8TTFyDFpXFWNKLorulQJnH-HZLhbZPsj5eYv0qDGjhM2u1CaxEHK7sMD_lam1K_WSHDoU9_sWgoojc6VhCApuqGZFj04DcTY/s1600/IMG_0121.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-csjs4StePjtkROlnlWU1K9VF8AW_JWrTyoDpXniNMQT8TTFyDFpXFWNKLorulQJnH-HZLhbZPsj5eYv0qDGjhM2u1CaxEHK7sMD_lam1K_WSHDoU9_sWgoojc6VhCApuqGZFj04DcTY/s320/IMG_0121.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Squaring corner clamp blocks</td></tr>
</tbody></table><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic0i1ZwTWcG3rMYyNabHEav-XU8ISXAJzbXwUejJFO60bN5QkFCA6NEdxqDA1fiQy1P6CtFYAZd208oBdr9f4xQCcAdlBiDBMn-uvOgRWzGImgIdzpnsmx83RkKrR01O5LFbkogGiYneY/s1600/IMG_0112.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEic0i1ZwTWcG3rMYyNabHEav-XU8ISXAJzbXwUejJFO60bN5QkFCA6NEdxqDA1fiQy1P6CtFYAZd208oBdr9f4xQCcAdlBiDBMn-uvOgRWzGImgIdzpnsmx83RkKrR01O5LFbkogGiYneY/s320/IMG_0112.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Shows drawer with bottom glued and nailed on.</td></tr>
</tbody></table><div><br />
</div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com1tag:blogger.com,1999:blog-5047635659384377481.post-52569471617024124262012-02-13T17:28:00.010-08:002012-03-09T22:54:00.473-08:00Full Extension Drawer Slide Mounting<div class="separator" style="clear: both; text-align: left;"><span style="text-align: -webkit-auto;">The method we use for installing a stack of drawers in <i>frameless cabinets</i> assumes the following:</span></div><div class="separator" style="clear: both; text-align: left;"></div><div style="text-align: -webkit-auto;"></div><ol><li>Drawer fronts will indent into opening</li>
<li>The spacing around the drawer front edge and cabinet wall will be 1/8"</li>
<li>The drawer slides will be side mounted</li>
<li>The top and bottom drawer will have a 1/4" clearance with the drawer opening cabinet edge</li>
<li>The spacing between drawers will be 3/8"</li>
<li>The drawer front height will be 1/4" larger than nominal drawer vertical size,i.e., a 1/8" lip</li>
</ol>The picture below shows an example cabinet with 5 drawers using this method. The above dimensions provide a 1/8" lip for the drawer front relative to the drawer body.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAGQkduXGySp1y64V89gHLWEjL89Bw8tLewSmq_aemYtDT_-bmWfuP7e2uqNZZ8nB1yn0Yxz-3lfKL-hN-JSrON_LcFPpjLsm3WmdTYOLm8BhWYBFYgEV9vF6m9SKNpSBUv0RRBZyFb_Y/s1600/IMG_0158.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjAGQkduXGySp1y64V89gHLWEjL89Bw8tLewSmq_aemYtDT_-bmWfuP7e2uqNZZ8nB1yn0Yxz-3lfKL-hN-JSrON_LcFPpjLsm3WmdTYOLm8BhWYBFYgEV9vF6m9SKNpSBUv0RRBZyFb_Y/s320/IMG_0158.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">5 Drawer cabinet on wheels using full extension slides.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">The first step is to determine cabinet slide positions for the drawer set. For example, the drawers shown above are: 2", 3", 3", 4" and 5". With the drawer slides mounted centered on the drawer sides, the following arithmatic will determine the slide positions:</div><div class="separator" style="clear: both; text-align: left;"></div><ol><li>2" drawer: 1/4 + 1 = 1 1/4", 1/4" for top spacing + 1" for 1/2 the drawer height.</li>
<li>3" drawer: 1 1/4 + 1 + 3/8 + 1 1/2 = 4 1/8", (2" drawer position) 1 1/4 + (remain drawer width) 1 + (drawer spacing) 3/8 + (1/2 3" drawer height) 1 1/2</li>
<li>3" drawer: 4 1/8 + 1 1/2 + 3/8 + 1 1/2 = 7 1/2"</li>
<li>and so on.</li>
</ol>So we have the following positions: 1 1/4", 4 1/8", 7 1/2". The next step is to mark these positions on the inside side of the cabinet measured from the inside top of the opening as shown below. The slides must be indented 9/16" from the front edge so when completed the drawers sit flush with cabinet front.<br />
<div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Step 3: position slide on a line centered in the screw holes. Mark two or three hole positions and use a nail or center punch ( I like a 1/16" center punch McMaster #34155A11 ) to make a starter hole for the screw, then screw slide in place.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3hZ02OuF17ifjz6_Ty9TU72fTJXiTItwDkGutu3Tk1Jy487cvXtPm-8aUp75ZhRHSYoexHwxJA5f-JEhHGxSkGgbuUVbgQTm6NNdHi1ICu7t6iDEJwYaCS4-EJiHEl_31c-vwIB3MiAE/s1600/IMG_0130.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3hZ02OuF17ifjz6_Ty9TU72fTJXiTItwDkGutu3Tk1Jy487cvXtPm-8aUp75ZhRHSYoexHwxJA5f-JEhHGxSkGgbuUVbgQTm6NNdHi1ICu7t6iDEJwYaCS4-EJiHEl_31c-vwIB3MiAE/s320/IMG_0130.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mounting cabinet full extension slides.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">Step 4: Mounting slide to drawer side. At either end of the drawer make a mark at 1/2 the drawer height and then draw the line.</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQuk8iUabDXXntSFBHhPA66j1-EZwUHWfF2FMouAYdQb02xhHK5q9_j18mYmu17D-pmVoA_ytsG7tOsoruM4Tc2WeJ09CFt3kFApOJfGmsDvsbZPu4VXFWaYeqKSBIFtifvsKsWVJx4DI/s1600/IMG_0169.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQuk8iUabDXXntSFBHhPA66j1-EZwUHWfF2FMouAYdQb02xhHK5q9_j18mYmu17D-pmVoA_ytsG7tOsoruM4Tc2WeJ09CFt3kFApOJfGmsDvsbZPu4VXFWaYeqKSBIFtifvsKsWVJx4DI/s320/IMG_0169.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Marking slide position on drawer.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMnwmXMLDQb3y32alWB3uHTO4ZxcUX5GAxeW_5BBS0-I_d55kUlRHXTHbvGQ7P2oMFElT4Fbp1-hgPjvsvpZnz42TC8R8G_5oWUqUjltj8ujFMk2S_SaR_vHuWrOy_M2qPdQ2B-AsBtr4/s1600/IMG_0170.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMnwmXMLDQb3y32alWB3uHTO4ZxcUX5GAxeW_5BBS0-I_d55kUlRHXTHbvGQ7P2oMFElT4Fbp1-hgPjvsvpZnz42TC8R8G_5oWUqUjltj8ujFMk2S_SaR_vHuWrOy_M2qPdQ2B-AsBtr4/s320/IMG_0170.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawing slide position line.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOiJRFiNhmKMsfi9nnhIYSiS42BIwc8SKhRu3nWuJuiRy2isVVdSpgyWuo6D1PBg0-SZyEV-kGp4dPfGiWmYigfUIozRbnBIZ9nKcJA8kZteNCVXUSZmqi5gAy4nf1dkPw0eXuG8thMw4/s1600/IMG_0112.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOiJRFiNhmKMsfi9nnhIYSiS42BIwc8SKhRu3nWuJuiRy2isVVdSpgyWuo6D1PBg0-SZyEV-kGp4dPfGiWmYigfUIozRbnBIZ9nKcJA8kZteNCVXUSZmqi5gAy4nf1dkPw0eXuG8thMw4/s320/IMG_0112.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Screwing slide to drawer.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">Step 5: Position slide on drawer with slide end aligned to drawer front as shown. Make starter holes and screw slide in position. Repeat for other drawer side.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Step 6: Insert the drawer into the cabient slides. When you push the drawer into position the first time you will encounter some resistance, since the bearings are repositioning themselves. Once the drawer is inplace this resistance should not occur. A couple of drops of DuPont Silicone lubricant on each slide before insertion will work wonders.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;"><b>Making the Drawer Fronts:</b></div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">The following method works for both full extension and Euro slides.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Step 1: From 1/2 (12 mm) plywood cut the front 1/4" smaller than the horizontal opening and 1/4" larger than the nominal drawer height. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><div class="separator" style="clear: both; text-align: left;">Step 2: With a 1/8"R round over bit dress the front edge of the drawer front. After filling any voids in the edge sand and seal the drawer front both sides. Then coat with polyurethane.</div><div class="separator" style="clear: both; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6v01RN1xvwh1EKecpmfLarsKLR-roJiWrH8ZALHs9vHHxwxTkRxUUBFQ9p68DmNLcdo7emgGuq9EMEXHWBoNJ13X3E7PxbjWCIJZxk74zwOLbMMIfXH8DT-Fwxj39jIWfSV0VU_wpE84/s1600/IMG_0182.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6v01RN1xvwh1EKecpmfLarsKLR-roJiWrH8ZALHs9vHHxwxTkRxUUBFQ9p68DmNLcdo7emgGuq9EMEXHWBoNJ13X3E7PxbjWCIJZxk74zwOLbMMIfXH8DT-Fwxj39jIWfSV0VU_wpE84/s320/IMG_0182.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawer front marked for handle.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">Step 3: Find vertical and horizontal of the drawer front and mark with pencil. Using center punch, mark position of handle holes. Then drill holes using a 3/16" brad pointed or dowel bit to prevent tearing around hole. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu4D854KMAuRFcfBgW8A8ihhas1Pp8IfjEv7vkbeNDoPkhVJd1iBK-sVGutJ4m95oQAh2cBWyc9XXhSTFUlrM7ViqUF5om7w4M6pzQuG_v_ywmTS-3L_J8EWSgpVMM9k87m-hICa6fdBE/s1600/IMG_0183.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiu4D854KMAuRFcfBgW8A8ihhas1Pp8IfjEv7vkbeNDoPkhVJd1iBK-sVGutJ4m95oQAh2cBWyc9XXhSTFUlrM7ViqUF5om7w4M6pzQuG_v_ywmTS-3L_J8EWSgpVMM9k87m-hICa6fdBE/s320/IMG_0183.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Front drilled for handle.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">Step 4: Clamp the drawer front to front part of the drawer. Use 1/8" spacers at bottom edge and center the front. Use a mini clamp to hold front in place will handle holes are drilled through. Insert handle screws from inside draw and fastened handle. If it was a wide drawer, 3/16" holes would be drilled through the front of the drawer at each end, then 3/4" #8 screws would be used to hold the drawer front in place. After that, drill and mount the handle. </div><div class="separator" style="clear: both; text-align: left;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtrX09kBpUSGIC1D1576Xqf-ago52_VfAYwz1XBFvE3D6CUrQfwxJt-mXx77okMDoQAYkGnNrT-VJ2wnJ2R6Xrl52N3lubQDliywh4Rzanm3YYqIf5-oNI8cr-R0HP-pOyLglIa_QLmgE/s1600/IMG_0185.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtrX09kBpUSGIC1D1576Xqf-ago52_VfAYwz1XBFvE3D6CUrQfwxJt-mXx77okMDoQAYkGnNrT-VJ2wnJ2R6Xrl52N3lubQDliywh4Rzanm3YYqIf5-oNI8cr-R0HP-pOyLglIa_QLmgE/s320/IMG_0185.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Squeeze clamp holding drawer front in place with 1/8" spacer at bottom edge.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">: </div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxlczTeKgPlFKpUQNXpnqdS9fYNpPORSbZYCVEKEnRzw464J5xBAVO75PPpjdVddvJWRRc4ik7mH2mS6JkUh8zxMM26FbANlAmvACSL3r6F4pjLxAhC8Vtfn1ng6drvaSLQ97dQYc3n4/s1600/IMG_0186.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhoxlczTeKgPlFKpUQNXpnqdS9fYNpPORSbZYCVEKEnRzw464J5xBAVO75PPpjdVddvJWRRc4ik7mH2mS6JkUh8zxMM26FbANlAmvACSL3r6F4pjLxAhC8Vtfn1ng6drvaSLQ97dQYc3n4/s320/IMG_0186.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Front positioned and ready to be drilled.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC2nGfjKTB0xYX4cqebf6T-wPu8BMVG8D-f6lXqX3B0nSv3xLrhvFqqhc3LLmEAEWiNW5tFmtd5HmA6HycaEyibl6je0Yg0JiYpCEmy9GfAA0XjHw0ndaAR4L0ef9Gj7Lpyn0rE5TpWyw/s1600/IMG_0187.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhC2nGfjKTB0xYX4cqebf6T-wPu8BMVG8D-f6lXqX3B0nSv3xLrhvFqqhc3LLmEAEWiNW5tFmtd5HmA6HycaEyibl6je0Yg0JiYpCEmy9GfAA0XjHw0ndaAR4L0ef9Gj7Lpyn0rE5TpWyw/s320/IMG_0187.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Finished drawer front.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: left;">Step 4: The method used above will not work for the top draw, so I use two small pieces of carpet tape on the front of the drawer. A spacer is used to space the drawer fronts. Set the drawer front at an angle on the spacer then tip the front forward until the tape is contacted. Clamp and drill handle holes.</div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-35413410278943105532012-02-13T17:26:00.011-08:002012-03-15T18:24:29.128-07:00Drill Press CabinetThe drill press cabinet is similar in design to the miter saw cabinet including a removable top panel. Though in the miter saw cabinet design the drawer front overlays the cabinets sides, I decided for this frame-less cabinet the draws would look better indented into the cabinet as seen in the picture below. In addition, I wanted the drawers to be 16" deep; therefore, full extension drawer slide were used. These are twice the price of the Euro slides but can carry bigger loads.<br />
<br />
As seen in the picture below, the bottom is open. This space could be use for additional drawers or storage space with an non-overlap door. The common euro door hinge is designed for 3/4 or full overlay; however, non-overlay versions are available from Lowes and other supplies.Using these hinges the door will inset to match the drawers and give nice clean lines.<br />
<br />
As with the other projects, this is a project using Kreg pocket screws. There are many ways that cabinets like this could be built, but this method is fast and the joint is strong. I have seen projects elsewhere that use brads and glue for assembly. But whatever the case, all the dimensions are here and you can use whatever method you want. For this project, the construction process is very similar to that used for the miter cabinet project.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhABNeBZWCNfXbdK5BUd0aUWg0SlADfyKMV0QotfUb7VjrkXRJL3zkMkuLJ7bGQutEnzzI6I0fBbrebobxtAb8K_n3urDmt9GjXJwwCQ8CQBpkRIhurpWPvMHMIap84NySqfuLytJ-Yw5I/s1600/IMG_0117.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhABNeBZWCNfXbdK5BUd0aUWg0SlADfyKMV0QotfUb7VjrkXRJL3zkMkuLJ7bGQutEnzzI6I0fBbrebobxtAb8K_n3urDmt9GjXJwwCQ8CQBpkRIhurpWPvMHMIap84NySqfuLytJ-Yw5I/s320/IMG_0117.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Completed cabinet with drill press.</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: center;"></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQ2vAJU-cj8nRzsfAM9uGV4VzoPzwlBwpY6hhagAvbH6AGrkxxCNTr_gITim2S5pHrWqLQ0AXPaYM7eB0n5HHih_YwM0W1b0x0YOZnFZKU5XRp69VX4qTCG1LKCKIxI-Yw8t_TyNsgJcc/s1600/IMG_0212X.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQ2vAJU-cj8nRzsfAM9uGV4VzoPzwlBwpY6hhagAvbH6AGrkxxCNTr_gITim2S5pHrWqLQ0AXPaYM7eB0n5HHih_YwM0W1b0x0YOZnFZKU5XRp69VX4qTCG1LKCKIxI-Yw8t_TyNsgJcc/s320/IMG_0212X.jpg" width="284" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back view showing cleats indented 3/16"</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3hIpg2RPLKtANrPnFfNANpDCf3synyQ18sq1U8H7GW-TO8q2Kbf709E6_Q-unyGJpk85WuwbEz5ndskSd4UaNy8wlrCXMliiu_423yJ_Q8QER_YWsCwaZ9U1gx_hyphenhyphen2CgM3T3y1LboL0g/s1600/IMG_0103.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi3hIpg2RPLKtANrPnFfNANpDCf3synyQ18sq1U8H7GW-TO8q2Kbf709E6_Q-unyGJpk85WuwbEz5ndskSd4UaNy8wlrCXMliiu_423yJ_Q8QER_YWsCwaZ9U1gx_hyphenhyphen2CgM3T3y1LboL0g/s320/IMG_0103.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Partly completed cabinet with 2 1/2" draw.</td></tr>
</tbody></table><b><br />
</b><br />
<b>BOM</b><br />
<ol><li>Sides: qty 2, 27 1/4" x 19 1/2"</li>
<li>Top/Bottom: qty 2, 22 1/2" x 19 1/2"</li>
<li>Standoff: qty 2, 11/2" x 19 1/2"</li>
<li>Top Plate: qty 1, 22 1/2" x 19 1/2"</li>
<li>Front Cleat: qty 1, 2" x 22 1/2"</li>
<li>Back cleat: qty 1, 3 1/2" x 22 1/2"</li>
<li>Corner Cleats: qty 2, 4" x 4" with diagonal cut</li>
<li>Caster blocks: qty 2, 4" x 3"</li>
<li>Back cleats: qty 5', 3/4" x 3/4"</li>
</ol>Material:<br />
<br />
<ol><li>18mm (23/32") Cabinet grade plywood, HD</li>
<li>Poplar plank 1/2", Lowes</li>
</ol><b>Drawers: A</b> detailed discussion of <a href="http://workshopprojects.blogspot.com/2012/02/simple-drawer-construction.html">drawer construction</a> can be found elsewhere in this blog. The picture below show one drawer for this project being constructed.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOYpGKN0HmSMOHFbVMobFfkYuUVWG5to28fwZbOHCmNTGLL1p7qt7ehtbRLbYAThH1ERmzIodEv9BSWreL2uOBEf9QyvRJWBo7NqvYA11d7F1rbMy_bg9j58yzekutVa5M5RC3es4rR7U/s1600/IMG_0115.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiOYpGKN0HmSMOHFbVMobFfkYuUVWG5to28fwZbOHCmNTGLL1p7qt7ehtbRLbYAThH1ERmzIodEv9BSWreL2uOBEf9QyvRJWBo7NqvYA11d7F1rbMy_bg9j58yzekutVa5M5RC3es4rR7U/s320/IMG_0115.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">4" drawer being assembled.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8byShQJWIHoeX7HBd5p19AjQETFzmhCZXDclPLScqKLUiunU-VofqMvZmdxdY3c_FK1HSfV5LPPnOgumgEhEjUwGgO5W2_vRlv1EeJcKYrKwQDVO8mj8G74IhIfqWVmVd2Mz88nYFOdg/s1600/IMG_0112.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8byShQJWIHoeX7HBd5p19AjQETFzmhCZXDclPLScqKLUiunU-VofqMvZmdxdY3c_FK1HSfV5LPPnOgumgEhEjUwGgO5W2_vRlv1EeJcKYrKwQDVO8mj8G74IhIfqWVmVd2Mz88nYFOdg/s320/IMG_0112.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Attaching drawer slides to drawer. Note center punch.</td></tr>
</tbody></table>The cabinet slide positions using 1/4" spacing at top and 3/8" between drawers. With this spacing the drawer fronts will be have a 1/8" lip top and bottom. The final look will be a 1/8" spacing between adjacent drawer fronts and the cabinet walls, as seen in the picture. The following assumes that the slides are centered vertically on the drawer sides.<br />
<br />
<ol><li>2/1/2" drawer: 1 1/4" + 1/4" = 1 1/2"</li>
<li>4" drawer: 1 1/2" + 1 1/4" + 3/8" + 2" = 5 1/8", position of top slide + remaining drawer height + 3/8" spacing between drawers + center of 4" drawer.</li>
</ol><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaMQCGI_UyiyR4k1_V2qL4aLuTimpimV2dzrRwkpJKtA09BfGR7rqiLHBVkK-3_NhHAeNhgT8QDdlkKnXhXx_E09NQp8xzkaBCJ7A88rJovH2IPrqXcfNeW-rIczn8VUNgzjhYvk7h6_Q/s1600/IMG_0106.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaMQCGI_UyiyR4k1_V2qL4aLuTimpimV2dzrRwkpJKtA09BfGR7rqiLHBVkK-3_NhHAeNhgT8QDdlkKnXhXx_E09NQp8xzkaBCJ7A88rJovH2IPrqXcfNeW-rIczn8VUNgzjhYvk7h6_Q/s320/IMG_0106.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mounting slides in cabinet.</td></tr>
</tbody></table><br />
<b>Drawer BOM:</b><br />
<br />
Drawer 2 1/2" x 16"<br />
<br />
<ol><li>Front/Back: qty 2, 20 9/16" x 2 5/16"</li>
<li>Sides: qty 2, 16" x 2 5/16"</li>
<li>Bottom: qty 1, 16" x 21 1/2" x 3/16"</li>
<li>Slides: 1 set full extension, 16" Liberty D80616C-ZP-W, HD</li>
</ol><br />
Drawer 4" x 16"<br />
<br />
<ol><li>Front/Back: qty 2, 20 9/16" x 3 13/16"</li>
<li>Sides: qty 2, 16" x 3 13/16"</li>
<li>Bottom: qty 1, 16" x 21 1/2" x 3/16"</li>
<li>Slides: 1 set full extension, 16" Liberty <span style="background-color: white; color: #222222; font-family: Arial, Tahoma, Helvetica, FreeSans, sans-serif; font-size: 13px; line-height: 18px;">D80616C-ZP-W</span>, HD</li>
</ol>Drawer Fronts<br />
<div><ol><li>2 1/2" Drawer: 22 1/4" x 2 3/4" x 12mm</li>
<li>4" Drawer: 22 1/4" x 4 1/4" x 12mm</li>
</ol><br />
Material for Drawers:<br />
<br />
<ol><li>12mm Blonde plywood, Lowes</li>
<li>3/16" underlayment, HD</li>
<li>1" Kreg screws</li>
</ol><br />
<br />
<div class="separator" style="clear: both; text-align: center;"></div></div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-20883182225694947052011-12-08T17:14:00.000-08:002011-12-09T14:00:46.722-08:00Miter Saw Dust AdapterI have been looking for a vacuum adapter to use with my 10" Craftsman miter saw. Shown below is the miter saw with a home made adapter using a PVC pipe fitting.<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBdIkQlHl228_4OxsN5EEvD-FbN4mVbNG27vAtsraxmMp7h1K_is-Xf1UMr7xOsGvwvPX-k7JBSuLK0dsKkiO5iKkTqgOMhHmHSGrh7f-Bv-3cARkDc8wjHVeNad6bzVZQHIs7ec4mg_Y/s1600/IMG_0084.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjBdIkQlHl228_4OxsN5EEvD-FbN4mVbNG27vAtsraxmMp7h1K_is-Xf1UMr7xOsGvwvPX-k7JBSuLK0dsKkiO5iKkTqgOMhHmHSGrh7f-Bv-3cARkDc8wjHVeNad6bzVZQHIs7ec4mg_Y/s320/IMG_0084.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Craftsman Miter Saw</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLp4QN3WvNegwk-N-5ez4b1AG60GJQXA0oyRAa6YSZN4Q0WGijytwOD5pD_AMSDWM_c_Th7tlbUQBPh7yyGSgwagHPVcnWr3a9nfz53F0wQbEStT5A_OMA74WweOAnRqu0dmLgblhX8X8/s1600/IMG_0090.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLp4QN3WvNegwk-N-5ez4b1AG60GJQXA0oyRAa6YSZN4Q0WGijytwOD5pD_AMSDWM_c_Th7tlbUQBPh7yyGSgwagHPVcnWr3a9nfz53F0wQbEStT5A_OMA74WweOAnRqu0dmLgblhX8X8/s320/IMG_0090.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Adapter made of 1 1/4 PVC fitting and slip nut.</td></tr>
</tbody></table><br />
<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: -webkit-auto;"><br />
</div>The adapter is made from a 1 1/4 inch PVC pipe fitting purchased at HD. Three holes have been drilled and tapped around the edge about 1/8" in for 8-32 machine screws. A slip nut which can be found with the sink fittings will hold the hose tightly.rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-68164183580696278862011-12-07T17:27:00.000-08:002011-12-07T17:27:23.626-08:00Dust SeparatorsA dust separator, DS, is a device to remove particles from the vacuum air stream without filters. The Dyson vacuum cleaner is an example of this process, using cyclonic airflow for separation. Cyclonic airflow works like a washing machine spin cycle, except instead of throwing water out it throws dust. For this discussion we will examine two devices available to the woodworking shop: The Dust Deputy and the Thein baffle.<br />
<br />
To be continuedrinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-69297190190820236492011-12-07T16:15:00.004-08:002012-03-15T18:32:14.519-07:00Miter Saw Cabinet<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCpdNA4KLZ1SQ3rB4VL6NZsKAefj135WaRngJAiCScL8edzKK-j9MZCvQNiP3tENUOrA_H_ht_0yEzKX2qYYKQGPqcB-FoUqjBxZXRQ9HDCq935ps3elFfKpmkltN5zZM2gKS1vtrt2WM/s1600/IMG_0095.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCpdNA4KLZ1SQ3rB4VL6NZsKAefj135WaRngJAiCScL8edzKK-j9MZCvQNiP3tENUOrA_H_ht_0yEzKX2qYYKQGPqcB-FoUqjBxZXRQ9HDCq935ps3elFfKpmkltN5zZM2gKS1vtrt2WM/s320/IMG_0095.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Basic compound miter saw cabinet without vac.</td></tr>
</tbody></table><br />
Well, I have some cabinet grade plywood left from wall cabinet building, so why not a CMS, compound miter saw, cabinet with wings. Here are two designs I found on the web<br />
<br />
<a href="http://mikefromwinton.com/mtrsaw.html">http://mikefromwinton.com/mtrsaw.html</a><br />
<br />
<a href="http://local.americanwoodworker.com/Mobile_Miter_Saw_Stand_Sun_City_Center_FL-r1332837-Sun_City_Center_FL.html">http://local.americanwoodworker.com/Mobile_Miter_Saw_Stand_Sun_City_Center_FL-r1332837-Sun_City_Center_FL.html</a><br />
<br />
Since I have a small shop, Mike's smaller design seems best; however, I like the full wings on the other design. The first part of this project will be to build the basic cabinet, a design that could also be used for other tools, such as, the drill press, band saw, etc. The wings will be added later.<br />
<br />
Specification:<br />
<ol><li>Same floor space as present metal stand, 24" x 20".</li>
<li>Two fixed and two locking 3" casters</li>
<li>Draw for tool accessories</li>
<li>Internal duplex power outlet</li>
<li>Extension arms both sides with fence, ruler, and stop.</li>
<li>Removable saw platform to accommodate 10" and 12" fixed and sliding saws</li>
<li>Built in vacuum/dust separator with autoswitch</li>
</ol>Note: See post on dust separators<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlq0FDW-F4tuIeCjT2kr1Hrnu5a9tqfzogMfJwIwIBQ2i1qChbtVIUFZYydthcOqk7_W0f7iw6aX1Z3H6KNpEDwQFtXGLd8qU9QVpRoTgSihgQuLo9dpiHFSocVy0pPlqZ9wK-S0Gf7WE/s1600/IMG_0080.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlq0FDW-F4tuIeCjT2kr1Hrnu5a9tqfzogMfJwIwIBQ2i1qChbtVIUFZYydthcOqk7_W0f7iw6aX1Z3H6KNpEDwQFtXGLd8qU9QVpRoTgSihgQuLo9dpiHFSocVy0pPlqZ9wK-S0Gf7WE/s320/IMG_0080.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Tool cabinet carcass </td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWxiDs1G8379lxDpH69aQtUvoUpLhNw5VqukIdq4Co0oZDF9hj3F4umTPTIMNmprtPbMgzb_f-1ejjG9rnlebipE0G0tGEfXo0yyOfwVdhsAv5QD8JshgxhZPRMZJv1Hr_RDGpIuK3434/s1600/IMG_0087.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWxiDs1G8379lxDpH69aQtUvoUpLhNw5VqukIdq4Co0oZDF9hj3F4umTPTIMNmprtPbMgzb_f-1ejjG9rnlebipE0G0tGEfXo0yyOfwVdhsAv5QD8JshgxhZPRMZJv1Hr_RDGpIuK3434/s320/IMG_0087.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Assembled base cabinet showing casters and draw slide.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA8qdpRWelaQ2fPGa70xWkt4TiprmOHlpfxXmt-K1IxS-hPlfqcl1IxvoSyRrCHySYBd-U9D3mEQHyI7dOfT43HKUVISF2v2QU9LBPLxS-u3XRv2J9IyWK9PzHChkPjHtlb0VnNGzLAEU/s1600/IMG_0088.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiA8qdpRWelaQ2fPGa70xWkt4TiprmOHlpfxXmt-K1IxS-hPlfqcl1IxvoSyRrCHySYBd-U9D3mEQHyI7dOfT43HKUVISF2v2QU9LBPLxS-u3XRv2J9IyWK9PzHChkPjHtlb0VnNGzLAEU/s320/IMG_0088.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">View of cabinet top and platform rails.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpCUCkkPwUAOkALuZMKKJQqp4eQiXTbx6G-1mqE-JM9FPKhJZL9m6ztQvQYUtHEecRZax730SVvRop2j2vBbI72-kkp81h9tB06b8Lfcah219NbxZqNpA09lsJpRSeSzab7w5dV5mNOhI/s1600/IMG_0089.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpCUCkkPwUAOkALuZMKKJQqp4eQiXTbx6G-1mqE-JM9FPKhJZL9m6ztQvQYUtHEecRZax730SVvRop2j2vBbI72-kkp81h9tB06b8Lfcah219NbxZqNpA09lsJpRSeSzab7w5dV5mNOhI/s320/IMG_0089.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">One of four 1/4" threaded insert for mounting platform.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5rKwFJmnkekKGawLWmafU6TEausjqvn_6BMrtu2BRCiwC_bNSJwrTcttbqnESYcpztG_zoeBxiEpeezYb3Mhg-ZAV0YJUrI6rKyWjN3NUsR52NM0xEW8JcTn0WEmmcMt3KUDDsDuOh8A/s1600/IMG_0091.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5rKwFJmnkekKGawLWmafU6TEausjqvn_6BMrtu2BRCiwC_bNSJwrTcttbqnESYcpztG_zoeBxiEpeezYb3Mhg-ZAV0YJUrI6rKyWjN3NUsR52NM0xEW8JcTn0WEmmcMt3KUDDsDuOh8A/s320/IMG_0091.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Electric outlet positioned for use with autoswitch.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuskUCH8UYZVqs0oFMHhiVz7oT7Wm3Qr1MRGHZd6u68MCWqaurU_EZuGyUz42Dt-URxMYlk-puaQcnT2JLenOj2Et0PfbVBY1M7Q4ghfTRuV7MFnE3lnXVuX8Mm2vduxOEkr91S1vQ9YA/s1600/IMG_0142.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhuskUCH8UYZVqs0oFMHhiVz7oT7Wm3Qr1MRGHZd6u68MCWqaurU_EZuGyUz42Dt-URxMYlk-puaQcnT2JLenOj2Et0PfbVBY1M7Q4ghfTRuV7MFnE3lnXVuX8Mm2vduxOEkr91S1vQ9YA/s320/IMG_0142.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back view showing vac and Sears auto-switch</td></tr>
</tbody></table><br />
The drawer design comes from Lowes Creative Ideas, BLOG, woodworking, titled, "Simplified Drawer Construction".<br />
<a href="http://www.lowescreativeideas.com/Community/lciblog.aspx?BlogCatID=a55f3c08-e173-491e-9b33-7ab76699c136">http://www.lowescreativeideas.com/Community/lciblog.aspx?BlogCatID=a55f3c08-e173-491e-9b33-7ab76699c136</a><br />
<br />
<br />
<div class="separator" style="clear: both; text-align: center;"></div><br />
<div>Bill of Materials: Base Cabinet</div><div><ol><li>2 pieces 20" x 28", sides</li>
<li>2 pieces 20" x 24", top and bottom</li>
<li>1 piece 20" x 23 15/16", platform</li>
<li>1 piece 20" x 3 1/2", top cleat</li>
<li>1 piece 20" x 5 1/2", bottom cleat</li>
<li>2 pieces 20" x 1 1/2", platform standoff</li>
<li>1 piece 24" x 2", front cleat</li>
<li>4 pieces 4 1/2" x 3", caster plates</li>
<li>1 piece 5 in x 3 ft poplar 1/2" plank for edging</li>
<li>2 pieces 22 1/16" x 3 3/4", 1/2" birch plywood, drawer front/back</li>
<li>2 pieces 16" x 4", 1/2" birch plywood, drawer sides</li>
<li>1 piece 22 1/2" x 16", 1/4" plywood, draw bottom</li>
<li>1 piece 4" x 23 3/4", 3/4 plywood, draw front</li>
<li>100 Kreg 1 1/4" course pocket screws</li>
<li>1 set 500mm Euro drawer slide, KV 1284 (Lowes)</li>
<li>2 3" casters fixed, HF</li>
<li>2 3" caster, swivel/locking, HF</li>
<li>4 1/4-20 threaded insert, McMaster <span class="Apple-style-span" style="background-color: white; font-family: Arial, Helvetica, sans-serif; font-size: 12px;">92105A200, ( note 3 )</span></li>
<li>1 15 ft extension cord</li>
<li>1 Electrical box with duplex plate</li>
<li>1 Duplex outlet</li>
</ol><b>Step by Step Construction of Basic Cabinet</b><br />
<ol></ol></div><div><ol><li>Cut out the sides, bottom, top and cleats, (see note 1)</li>
<li>Drill pocket holes on the underside of the top and bottom pieces</li>
<li>Drill pocket holes in both cleats</li>
<li>Using glue, assemble cabinet carcass, (see note 2)</li>
<li>Glue and clamp front cleat under top at front</li>
<li>Glue caster plates in place</li>
<li>Glue platform standoff to top, see picture</li>
<li>Cut platform to size, round over and sand</li>
<li>Drill 1/4" holes 3/4" in from corners</li>
<li>Place platform in place on standoffs and transfer 1/4" holes to standoff</li>
<li>Drill standoff holes to 21/64", 7/8" deep</li>
<li>Cut 1/2" poplar plank into 3/4" strips</li>
<li>Using glue and brads add poplar strips to front edge of cabinet</li>
<li>Cut 1/2" poplar 24" x 2 3/4" and glue to front cleat.</li>
<li>Sand cabinet and round edges with 1/8" router round over bit.</li>
<li>Seal cabinet with Bullseye Sealcoat</li>
<li>Install 1/4-20 threaded inserts in standoffs, put instant glue on threads first.</li>
<li>Mount casters with 5/16" x 1" lag screws, left side fixed right side swivel</li>
<li>Mount electrical outlet</li>
<li>Mount drawer slides, 4 1/4" below front cleat</li>
</ol></div><div><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgR_FAFzzYSQ6OZlt-LHa0W04yk0icTm1RrVIy4SS4KAZdGAcXXYWswIdQKa4X6TK-l9js-gcMfcS-EwZmVtHo-45q7JhxlMLoOYL5IA2NFSNKIiieWYUBgJoP2h4-zlBUpI0TrbWVlkWI/s1600/IMG_0093.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgR_FAFzzYSQ6OZlt-LHa0W04yk0icTm1RrVIy4SS4KAZdGAcXXYWswIdQKa4X6TK-l9js-gcMfcS-EwZmVtHo-45q7JhxlMLoOYL5IA2NFSNKIiieWYUBgJoP2h4-zlBUpI0TrbWVlkWI/s320/IMG_0093.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Draw at full extension.</td></tr>
</tbody></table><b><br />
</b><br />
<b>Step By Step Construction of Drawer</b></div><div><ol><li>See Lowes Creative Ideas blog, "Simplified Drawer Construction"</li>
<li>Build a drawer using this method, 16" x 23" x 4" </li>
<li>Cut drawer front from 3/4" plywood</li>
<li>Edge drawer front with 1/2" poplar</li>
<li>Sand round and seal</li>
<li>Mount drawer front to drawer, centered left to right with 1/4" lip at bottom</li>
<li>Attach drawer using #10 x 1" screws from inside drawer</li>
</ol><br />
<ol></ol></div><div><b>Step By Step Construction of Wings</b></div><div><ol><li>To be completed. </li>
</ol></div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-11365691027047539502011-09-14T19:29:00.005-07:002012-03-11T10:29:50.021-07:00Drill Press Accessaries and SecretsWhat we will do in this section:<br />
<ul><li>Examine an older 10" Craftman drill press for problems</li>
<li>Add a keyless chuck</li>
<li>Build a drill press table</li>
</ul><br />
<u><b>Drill Press Secrets</b></u><br />
<br />
A good drill press with a table will make building the CNC router easier. This means drilling holes at ninety degrees to the surface, the right size and in the right place, but with a lot less frustration. What follows is a discussion of the features of a good drill press that can be used to improving yours or buy one.<br />
<br />
First, take a look at the excellent article by Grant Erwin,<a href="http://www.blogger.com/goog_1912655010"> </a><a href="http://www.tinyisland.com/htbdrillp.txt">http://www.tinyisland.com/htbdrillp.txt</a>, on how to buy a drill press and can also be used to examine your drill press to see how it stacks up. I have a Craftman 10" drill press that I bought several years ago which I need to examine, closely. Before we start that, here are two other articles worth looking at: <a href="http://www.victornet.com/reference/Drill_Chuck_Mounting.html">http://www.victornet.com/reference/Drill_Chuck_Mounting.html</a> and <a href="http://www.jacobschuck.com/drill-chuck-install.asp">http://www.jacobschuck.com/drill-chuck-install.asp</a>.<br />
<br />
<b>What is Runout?</b><br />
<br />
Runout is the wobble at the drill bit. Most bench top drill presses come with cheap chucks which are probably the biggest source of runout. To measure runout you will need a dial indicator and some way to hold the indicator. First, chuck up a dowel pin and place the indicator against the shaft. A Forstner or a starter bit will also work. Rotate the chuck by hand and read the extremes of the indicator measurement. If this indicates there is .003" or more runout, then place the indicator against the chuck itself. If the runout there is less that .002" then the jaws of the chuck are bad. If the runout at the chuck is bad then remove the chuck and check the spindle taper in the same way. If that checks good, buy a new chuck. A good quality drill press will have less than .002" runout at the bit. If the runout at the taper is greater than .002", you will need a new drill press.<br />
<br />
I have an old 10" swing, Craftman drill press and there is visible runout. I will measure the bit, chuck and taper runout of this press and post the pictures here. The measured runout at the Forstner bit shaft is .013", at the chuck it is .002" and at the taper less than .001". Apparently, the jaws themselves are damage or worn.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeVKByPVJKffm3VT7kqKQKf6ymMQUToFtQfzLo5yAX9bNAV3iKOf6X_2Cz_SAzLtlM2N34jzkGnuBSeZyhBLMYpyWuxUNWeIVHzSL53C3p407MKnDeAUp78yqPfgpxFi6egow_6Mp8q9-B/s1600/100_0972.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjeVKByPVJKffm3VT7kqKQKf6ymMQUToFtQfzLo5yAX9bNAV3iKOf6X_2Cz_SAzLtlM2N34jzkGnuBSeZyhBLMYpyWuxUNWeIVHzSL53C3p407MKnDeAUp78yqPfgpxFi6egow_6Mp8q9-B/s320/100_0972.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drill press with chuck removed. Drifts sitting on chuck.</td></tr>
</tbody></table><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNAsJH9fzSolHmuDkaxkZTLhLbL20AXBO53TqRYogiP1y3Yqk9fnYVSOqdP8h8zWh7ch54FZDNg1Wd_Bl5tB9naI3VgQBuzT3yBWjXBd9hAV4oCWKdE2XIPG1E4zRroDvlOaUvFqTmLc7X/s1600/100_0964.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNAsJH9fzSolHmuDkaxkZTLhLbL20AXBO53TqRYogiP1y3Yqk9fnYVSOqdP8h8zWh7ch54FZDNg1Wd_Bl5tB9naI3VgQBuzT3yBWjXBd9hAV4oCWKdE2XIPG1E4zRroDvlOaUvFqTmLc7X/s320/100_0964.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Indicator against forstner bit.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZr2KNi9O-7GkZan0i0iMAas-iL9dAnr0oP0AlpUjZKESgehvxTBuL2ybAplj2ADJ2eh-9A6SdlQ_Gaw1pb38VT8MKOGgaqqG0XwyD0AklqebEkNq9-jZq4TwCtpC1xaQYl1OTVsACD6rD/s1600/100_0967.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhZr2KNi9O-7GkZan0i0iMAas-iL9dAnr0oP0AlpUjZKESgehvxTBuL2ybAplj2ADJ2eh-9A6SdlQ_Gaw1pb38VT8MKOGgaqqG0XwyD0AklqebEkNq9-jZq4TwCtpC1xaQYl1OTVsACD6rD/s320/100_0967.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Indicator against chuck body.</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5xePqrlY6zF2TBbBSTCgmmErQJJLKhyoMyiqZxSSaio6CK7aOEJOU6H9GXMbli-5w3p3qC-vAqyQyiuXwBCqnxjxBRLZ-Koyqn50MHeQkxe5-kL2QS9W4Ic0DSIViWb3TUQ1k1zUJfQpX/s1600/100_0981.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5xePqrlY6zF2TBbBSTCgmmErQJJLKhyoMyiqZxSSaio6CK7aOEJOU6H9GXMbli-5w3p3qC-vAqyQyiuXwBCqnxjxBRLZ-Koyqn50MHeQkxe5-kL2QS9W4Ic0DSIViWb3TUQ1k1zUJfQpX/s320/100_0981.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Indicator against taper JT33 taper.</td></tr>
</tbody></table><br />
The chuck is held onto a JT33 taper with a screw up inside the jaw which I removed Attempts to dislodge the jaw have failed. A chuck removal drift set has been ordered from <a href="http://www.wttool.com/index">Wholesale Tools</a> and will arrive Friday along with a keyless chuck and a wiggler. The drift consists of two U shaped pieces of tapered steel. If you have a large bench or a floor drill press, the jaw is probably mounted on an arbor made up of a JT33 and a Morse MT2 tapers. To remove the arbor you will need a MT2 drift.<br />
<br />
Before the new chuck was installed, the taper both on the drill press and the chuck were cleaned with low odor mineral spirits. The new keyless chuck was placed, lightly, onto the JT33 taper and pushed up hard. Making sure that the chuck jaws are inside the chuck, I placed a piece of wood against the bottom of the chuck and struck upwards with a hammer, a couple of good raps. This chuck does not use a screw, as the old chuck did, so if the chuck isn't well seated it will fall off. The picture shows the chuck in place. Measured runout is now .001".<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRrZT3tFkqreIVEbGkPTz2niP6frLD8SnaHQMqZnFN5fcsYf8doSFnYvUrG_02b7xIQK-qQjdCX4RxY4P2X33WxJZz9MIp9Y_wW3_A40CRmqxEvI4fQZknUZA28p8Ol4wQVI02vNPGoH28/s1600/100_0993.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRrZT3tFkqreIVEbGkPTz2niP6frLD8SnaHQMqZnFN5fcsYf8doSFnYvUrG_02b7xIQK-qQjdCX4RxY4P2X33WxJZz9MIp9Y_wW3_A40CRmqxEvI4fQZknUZA28p8Ol4wQVI02vNPGoH28/s320/100_0993.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Keyless chick in place.</td></tr>
</tbody></table><br />
<b>More coming</b><br />
<br />
Sources: Harbor Freight, Wholesale Tools, Victor Machine Exchange<br />
<br />
<u><b>Making a Drill Press Table:</b></u><br />
<br />
Though you could build the CNC Router without a drill press table, it will make aligning and drilling the holes in the project parts easier. Besides it is a useful rig to have in a woodworking shop.<br />
<br />
A bench top drill press with a 10 inch swing, where the swing is twice the distance from the post to the drill bit, should be acceptable. Most of the readily available bench drill presses have problems which you will find by reading the reviews. The important points of precision are runout and perpendicularity where runout is the wobble at the chuck. This wobble will result in an oversize hole being drilled which would allow the precision rod of the CNC router to wobble. Perpendicularity can be adjusted using shims under the drill press table.<br />
<br />
The drill press table is a very handy woodworking accessory and is typically 12" by 24" with an adjustable fence. See the picture below. This table was made by laminating two sheets of 1/2" and 3/4" MDF with wood glue. Two aluminum T-Tracks which are 14" apart and 11 3/4" long were purchased from Amazon. These tracks use 1/4" hex head bolts to position the fence and clamp work pieces in position. The fence shown here is 2" high and is made by laminating a 3/4" birch plywood to 1/2" MDF. Two 9/32" holes are drilled vertically through the fence 14" apart. 3" hex bolts with knobs hold the fence in place. This table is bolted to the drill press table with 1/4" carriage bolts. Two coats of Zinnser Sealcoat is used to seal the table. Sealcoat is not water based and will not raise the surface of the MDF.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM9L9FpOAOtR_A7m9mq5fpOAPS-ZvxIb8A1RYJYUrTTWoGDJNWzu-v6IyOM4PBjEtj9tT3Nlyz9oxiMf8-l0SZ3pu3SY4k2ga00m6gNKGPdUvf9lFj6Vnt2IJ9mc37rcngWz4WcFG15O9p/s1600/100_0950.JPG" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhM9L9FpOAOtR_A7m9mq5fpOAPS-ZvxIb8A1RYJYUrTTWoGDJNWzu-v6IyOM4PBjEtj9tT3Nlyz9oxiMf8-l0SZ3pu3SY4k2ga00m6gNKGPdUvf9lFj6Vnt2IJ9mc37rcngWz4WcFG15O9p/s320/100_0950.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drill press table with simple fence.</td></tr>
</tbody></table><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMcekLP9fCMMsldnUCSLUTY_D5ojnGZE2dvzTqcYwQl8uThov2tvzDn7ZS_zGsrx23bIZQeGe8ECxBirtst5JdZWHr0ONKEXHTUOpnOS939I6_9y1uYhA_h2myAn9Wky2F8vXzwjF5JHfW/s1600/100_0952.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgMcekLP9fCMMsldnUCSLUTY_D5ojnGZE2dvzTqcYwQl8uThov2tvzDn7ZS_zGsrx23bIZQeGe8ECxBirtst5JdZWHr0ONKEXHTUOpnOS939I6_9y1uYhA_h2myAn9Wky2F8vXzwjF5JHfW/s320/100_0952.JPG" width="320" /></a></div><br />
This table was built 13" wide and is the reason the T-Track appears to be short.<br />
<br />
List of Materials:<br />
<ol><li> MDF, Homedepot</li>
<li>Poplar edging, HomeDepot or Lowes</li>
<li>T-Track, Amazon from Router Table Depot, $8.25 pair</li>
<li>Knobs, Incra Build-It set, Amazon, $10.99</li>
<li>Additional Hardware, Lowes or HomeDepot</li>
</ol>The cost of the basic table is about $25.<br />
<br />
An additional fence is in the work which is 4" high and incorporates a Incra T-Track Plus that includes a sliding scale, $14. at Amazon. The adjustable stop is from Peachtree, $7. This will be pictured once completed.rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-1947834034051905612011-09-14T19:28:00.020-07:002012-03-06T15:53:46.229-08:00Making a Router Table TopA router table is not a necessary tool for building the CNC router, but I have wanted one for a long time and now is the time to build it. This is a standard size table, 32" by 24" and includes a 4" fence. Here are the steps.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYi9kv4HLMTPqcvpyRbvuCHDJ5bdGp6K5a5jRZIKzgpLIDwPZzv_84ERfAXubIyRApJaBgIQM_NeWVtp7NaZrh_SStnKJfg8eXFdzgHhKoVr6TRVe3racDJAGOK0hiY6ZUojcgFuijkMY/s1600/scan0005x.tif" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="237" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYi9kv4HLMTPqcvpyRbvuCHDJ5bdGp6K5a5jRZIKzgpLIDwPZzv_84ERfAXubIyRApJaBgIQM_NeWVtp7NaZrh_SStnKJfg8eXFdzgHhKoVr6TRVe3racDJAGOK0hiY6ZUojcgFuijkMY/s320/scan0005x.tif" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Drawing of Router Top</td></tr>
</tbody></table><br />
<div class="separator" style="clear: both; text-align: center;"></div><b>Step by Step</b><br />
<ol><li>The surface is made like the drill press table. Start by layering a 1/2" MDF and 3/4" MDF sheets 33" by 24". Using weights and clamps, glue them together with wood glue. Spread the glue evenly with a plastic joint compound knife. Take the time to align the 24" width maybe even using some clamps. Don't worry about the 32" length since that will be trimmed to length. If you are using wider pieces of MDF say 25" by 33" then don't worry about getting the side perfectly aligned.</li>
<li>Using a table saw or hand saw with a guide, cut the width to 24", if you have used 25". Using a table saw sled or hand saw with a guide, cut the length to 32". Make sure you get it square.</li>
<li>At this point you can bond Formica to the surface with contact cement. Since this material is expensive ($50. 4 by 8 sheet, Lowe's), I opted not to use it, but coated it with oil based urethane instead. To make the surface slick, I use a few drops of <span style="color: #282828; font-family: Helvetica, Arial, sans-serif; font-size: x-small;">DuPont 4 Oz. Non-Stick Lubricant and polish it in.</span></li>
<li>Edge the table with poplar or oak and round over with a 1/8" round-over router bit.</li>
<li>Sand the edges and the MDF (lightly), then coat all surfaces with Sealcoat by Zinnser.</li>
<li>Make a template for the router plate. Start by cutting 16" lengths of 3/4" by 2 1/2" (1 by 3) straight fir or poplar.</li>
<li>Place the router plate on a flat surface and the place the 16" pieces as shown in the picture below. Insert some thin cardboard between the plate edge and the wood as shims. I used cardboard from a toothpaste box. Shimming the template like this will ensure that the routed inset will be a little larger that the router plate. If you do not do this, the plate will not fit into the hole cut into the table. Now use (Kreg) pocket screws to assemble template. See finished template.</li>
<li>Clamp the template to the table as shown. Now, set a 1/2" by 1/2" pattern router bit to a depth equal to the thickness of the template plus the router plate edge. The template bit is 1/2" diameter with 1/2" blades and has a 1/2" bearing above the bit so that it rides along the plate template. Notice that the plate is in the very center of the table.</li>
<li>After routing the groove, drill a 1/4" hole at the corner and cut the center out with a jig saw leaving a 3/8" lip.</li>
<li>Using the jig shown below, cut the rabbits for the T-track and miter track. Make multiple pass increasing the depth 1/16" on each pass. If you don't do this, the bit may wander. Remember to wear a sanding mask. MDF dust ain't friendly stuff. The T-track groove is 1/2" deep by 3/4" wide and the miter channel is 1 1/8" wide by 1/2" deep. See drawing for length demensions.</li>
</ol><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0GbLb3L54vbDRlgkSUUd5yorLplZUwgWYoT7JCX0fSkPJ8LFpDK5blKuv-37ebObj2RiQ86qIA7f_F1WHvBhjbphp-9yXjiARTdK3V7HL5L3MGaD8x8VTTwyfWOibYyflsfeDT9Ra9Q4c/s1600/101_1005.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0GbLb3L54vbDRlgkSUUd5yorLplZUwgWYoT7JCX0fSkPJ8LFpDK5blKuv-37ebObj2RiQ86qIA7f_F1WHvBhjbphp-9yXjiARTdK3V7HL5L3MGaD8x8VTTwyfWOibYyflsfeDT9Ra9Q4c/s320/101_1005.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Completed router plate template clamped in place.</td></tr>
</tbody></table><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAChtd7peBj9WssDAnvToi60oS2G1bK2kMpPDL-zi6cfu1r3-BvGmWPbouTYs285kJTLQpIpx0s1rIYAMmEImjjHdj0bo-QZCPUMhS4jXeGqoBkVzzPGFCBMX8elBk62sXkduNvWN3zIuY/s1600/101_1016.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAChtd7peBj9WssDAnvToi60oS2G1bK2kMpPDL-zi6cfu1r3-BvGmWPbouTYs285kJTLQpIpx0s1rIYAMmEImjjHdj0bo-QZCPUMhS4jXeGqoBkVzzPGFCBMX8elBk62sXkduNvWN3zIuY/s320/101_1016.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Routed plate lip. Jigsaw used to cut out center.</td></tr>
</tbody></table><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK2A81P_Q8DDZLjolb1tvuDTXdacvPU_9buLFDYYNJpoTgls2UjM1ZRG2J48VCecOwFDipu4VeEIzB-uGK9D5oFyu1ce5wqCCMMjHIrjnKcX-XnoUI5vFvwC-Mj7u4M2UXfrrcx9h-L5sb/s1600/101_1018.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjK2A81P_Q8DDZLjolb1tvuDTXdacvPU_9buLFDYYNJpoTgls2UjM1ZRG2J48VCecOwFDipu4VeEIzB-uGK9D5oFyu1ce5wqCCMMjHIrjnKcX-XnoUI5vFvwC-Mj7u4M2UXfrrcx9h-L5sb/s320/101_1018.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Center removed leaving 3/8" lip.</td></tr>
</tbody></table><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGPGz5wAkL_ETkYilKCK5GPGAMt822AT8v-27pF0eYD9neXF-kt_Tg4vuzd9I2NulejF6pJwl36JY5urcsd9WNiQori7McxWIcB9o6DligQQj3l2BhXLnIp1XO4s25jI2VY6AjIWUyQ4C1/s1600/101_1026.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjGPGz5wAkL_ETkYilKCK5GPGAMt822AT8v-27pF0eYD9neXF-kt_Tg4vuzd9I2NulejF6pJwl36JY5urcsd9WNiQori7McxWIcB9o6DligQQj3l2BhXLnIp1XO4s25jI2VY6AjIWUyQ4C1/s320/101_1026.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Jig for routing miter and T-track slots</td></tr>
</tbody></table><div><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnZEqW8WWWBqHhgX-L21ouA7QrTWDJ6VXK9wM97d2wN1GoqTVFIUn3vBWq-TOkg1fcSS6yV2jSPqFlZkyWtYTrC4a4fQ4C-zPJh6gmhgkS8i5Jj1zPh1PDSG5UhmsVK2OcPOlblM-FjYs/s1600/jfc_miterchannel_main.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="208" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhnZEqW8WWWBqHhgX-L21ouA7QrTWDJ6VXK9wM97d2wN1GoqTVFIUn3vBWq-TOkg1fcSS6yV2jSPqFlZkyWtYTrC4a4fQ4C-zPJh6gmhgkS8i5Jj1zPh1PDSG5UhmsVK2OcPOlblM-FjYs/s320/jfc_miterchannel_main.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Incra miter channel</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfRobQ72NOOIEVblUWfTqqRd2TQwvKYeKRYbdVMT2MRlDBb7Q5vuxvNi96ywEuL-oRT8XGvaZQxfqAVkzd1CBmZ0mem9drC-m5UEN4kHdRpgORfT_q4Bekhk0uh3SrwUdvw_aHMp223NY/s1600/buildit_ttrackreg_main.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="186" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfRobQ72NOOIEVblUWfTqqRd2TQwvKYeKRYbdVMT2MRlDBb7Q5vuxvNi96ywEuL-oRT8XGvaZQxfqAVkzd1CBmZ0mem9drC-m5UEN4kHdRpgORfT_q4Bekhk0uh3SrwUdvw_aHMp223NY/s320/buildit_ttrackreg_main.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Incra T-track</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgry9dQie_yOq28KHuDEvO2n7ZgMy7C0mhZStAaiTQIE84ThqbHLNWIl0NGoqBXpLmZJ7W_T46xfa1HENZjgEfoSel63WOZ-NVKuTirGyRflc7nf4ImcsMWKcp7UweObgk6Jh-9J78en0h/s1600/101_1030.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgry9dQie_yOq28KHuDEvO2n7ZgMy7C0mhZStAaiTQIE84ThqbHLNWIl0NGoqBXpLmZJ7W_T46xfa1HENZjgEfoSel63WOZ-NVKuTirGyRflc7nf4ImcsMWKcp7UweObgk6Jh-9J78en0h/s320/101_1030.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Completed router table</td></tr>
</tbody></table></div><div><b>BOM</b><br />
<ol><li>Qty 1 3/4" x 2' x 4' MDF HomeDepot</li>
<li>Qty 1 1/2" x 2' x 4' MDF HomeDepot</li>
<li>Qty 1 1/4" x 6" Oak Lowes</li>
<li>Qty 1 Rousseau router plate 3509 with snuggers, Amazon</li>
<li>Qty 1 24" inch T-track Incra <span style="background-color: white; font-family: Arial, Helvetica, sans-serif; font-size: x-small;">TTRACKREG24</span>, Amazon</li>
<li>Qty 1 32" Miter channel Incra, Amazon</li>
<li>Qty 1 4 oz <span style="font-family: inherit;"> <span style="color: #282828;">DuPont Non-Stick Lubricant</span></span></li>
<ol></ol></ol><b>Tools:</b></div><div><ol><li>Table saw</li>
<li>Jig saw</li>
<li>Router</li>
<li>Router bit, MCLS #6509, 1/2" pattern bit</li>
<li>Router bit, round over 1/8" MCLS #6350</li>
</ol></div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com2tag:blogger.com,1999:blog-5047635659384377481.post-83662448259758238172011-09-14T19:26:00.001-07:002011-09-18T16:06:56.659-07:00Shop Filter Blower<div style="margin-bottom: 0in;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrobgepVeCidFr7SO5jKAZXaPvnHqpJssICosJwUTPxBzhkxuXWBel74CQwTOhW2FL_yhf0VLx7T28VauE6wXL73K_dyILqd8CzQdMZgFHFq-CY0-BNnOT92mSvXqmn6x6GBJVrODQSc09/s1600/IMG_0046X.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="192" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrobgepVeCidFr7SO5jKAZXaPvnHqpJssICosJwUTPxBzhkxuXWBel74CQwTOhW2FL_yhf0VLx7T28VauE6wXL73K_dyILqd8CzQdMZgFHFq-CY0-BNnOT92mSvXqmn6x6GBJVrODQSc09/s320/IMG_0046X.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Filter blower is 12"x24"x30"</td></tr>
</tbody></table><br />
I received a filter blower kit from PennState in 2006 as a present and it has been sitting on a shelf in my shop ever since. PennState no longer sells this kit, but does sell a complete unit for $299. plus shipping as the AC620. Because I have recently been working with MDF, I decided it was time to build the kit. (Note: This filter does not eliminate the need for a face mask will working with MDF.)</div><div style="margin-bottom: 0in;"><br />
</div><div style="margin-bottom: 0in;">Since the kit is no longer available, this project is presented as a complete construction project with a full set of parts which can be purchased thru Grainger, PennState and other vendors.<span style="font-size: small;"> The cost of this project should be around $200 with the biggest cost being the blower ($90 to $120). Check the surplus houses using Goggle for possible substitutes. I found the Dayton 1TDR9 on Amazon for $120. delivered.</span></div><div style="margin-bottom: 0in;"><br />
</div><div style="margin-bottom: 0in;">MDF produces a fine dust during routing, cutting and sanding requiring the use of a filter mask. The dust particles generated are about the same size as when sanding pine; however, MDF contains formaldehyde. Some of the particles created are sub-micron which can stay airborne for many hours and can be inhaled and imbedded in lung tissue. If you will be working with MDF the bag filter used in this project should be a MERV 14 such as the Grainger, 6B660. The PennState came with a MERV 12 filter which will not extract sub-micron particles from the air.<br />
<br />
Filters are rated based on their ability to remove particulates from the air. The <span class="Apple-style-span" style="background-color: white; font-family: sans-serif; font-size: 13px; line-height: 19px;"><a href="http://en.wikipedia.org/wiki/American_Society_of_Heating,_Refrigerating_and_Air-Conditioning_Engineers" style="background-attachment: initial; background-clip: initial; background-color: initial; background-image: none; background-origin: initial; color: #0645ad; text-decoration: none;" title="American Society of Heating, Refrigerating and Air-Conditioning Engineers">American Society of Heating, Refrigerating and Air-Conditioning Engineers</a> has defined the <a href="http://www.mechreps.com/PDF/Merv_Rating_Chart.pdf">MERV</a> rating system for filters. A HEPA filter in this chart corresponds to a MERV 15 or better. For our purposes we have chosen a MERV 12 as a prefilter and a MERV 14 as the post filter. This combination should do a good job of sweeping the shop air of unwanted particles at a reasonable cost ($50.) which will be good for us and finishing projects. Remember as the prefilter loads up the back pressure on the fan will increase lowing the CFM and increase sweep time.</span><br />
<span class="Apple-style-span" style="background-color: white; font-family: sans-serif; font-size: 13px; line-height: 19px;"><br />
</span></div><div style="margin-bottom: 0in;">If you have a small shop and do not which to build this project you might investigate Shop Fox W1746 which can be purchased thru Amazon for $100. This unit claims to remove 0.3 micron particles and has 200 cfm air flow which should cycle a 10ft by 10ft shop every 5 min.</div><div style="margin-bottom: 0in;"><br />
</div><div style="margin-bottom: 0in;"><span style="font-size: small;">If you like quiet in your shop when you are not running tools, then this is probably not the filter blower for you, since the squirrel cage blower is noisy. A better design would use a reverse impeller fan such as the EBM R2E220-AA44-23 and sounds like a great project for the future.</span></div><div style="margin-bottom: 0in;"><br />
</div><div style="margin-bottom: 0in;"><span style="font-size: small;">Finally, before we start building, if all this information about sub-micron particles and lung damage has you freaked out, then you might be interested in a low cost particle counter, the <a href="http://www.dylosproducts.com/dcproairqumo.html">Dylos DC1100 PRO</a> with PC interface for $290.</span></div><div style="margin-bottom: 0in;"></div><br />
BOM:<br />
<br />
Wood<br />
<ol><li>2 pieces 1/2" plywood 30" x 23 7/8"</li>
<li>2 pieces 1/2" plywood 30" x 12 7/8"</li>
<li>1 pieces 1/2" plywood 23 11/16" x 11 11/18"</li>
<li>4 pieces 3/4" x 3/4" poplar, 25 3/8"</li>
<li>4 pieces 3/4" x 3/4" poplar, 10 1/4"</li>
<li>4 pieces 3/4" x 3/4" poplar, 23 3/4"</li>
</ol>Parts<br />
<ol><li>Blower: Dayton 1TDR9</li>
<li>Bag filter: Grainger 6B677 or Pennstate Ind. AC655</li>
<li>Pre filter: Pennstate Ind. ACPF, (24" x 12" x 1/2")</li>
<li>Electrostatic: Pennstate Ind. ACES1224</li>
<li>Switch: Mouser # <span class="Apple-style-span" style="background-color: white; color: #333333;"><span class="Apple-style-span" style="font-family: Times, 'Times New Roman', serif;">540-SRB22A2FBBNN</span></span></li>
<li><span class="Apple-style-span" style="background-color: white; color: #333333;"><span class="Apple-style-span" style="font-family: Times, 'Times New Roman', serif;">Power Entry Module:</span></span><span class="Apple-style-span" style="font-family: Times, 'Times New Roman', serif;"><span class="Apple-style-span" style="background-color: white; color: #333333;"> Mouser # </span><span class="Apple-style-span" style="background-color: white; color: #333333;">562-723W-X2/03</span></span></li>
<li><span class="Apple-style-span" style="font-family: Times, 'Times New Roman', serif;"><span class="Apple-style-span" style="background-color: white; color: #333333;">Wire: 18 gauge hookup</span></span></li>
</ol>Alternate Filter<br />
<ol><li>Pre filter: 24" x 12" x 1" ( Lowes, etc.). Use this filter with bag filter. A standard filter should be about 23 1/2" x 11 1/2" x 3/4". The opening in the box is 23 7/8" x 11 7/8" using 1/2" plywood. </li>
</ol>Plywood: For this project I am using Sandeply from HomeDepot, but birch will also work. I had HomeDepot cut a 4' x 8' sheet of 1/2" Sandeply into three pieces, two being 31" x 48". By the way, Sandeply is not 1/2" thick, but 15/32".<br />
<br />
Construction Steps:<br />
<br />
<ol><li>Cut all the plywood panels to size.</li>
<li>On the inside of each panel, mark the positions of the 3/4 x/3/4 cleats. The cleats for the filters are positioned 2" from one end and the fan plate cleat, 5/8" from the other end.</li>
<li>Rather than use clamps and glue to assemble the box, I used Kreg micro block and pocket screws with glue. In the photo below, you can see that one of the box sides is held vertical using the jig shown. Wax paper was used on the bench surface to prevent the pieces from bonding to the bench.</li>
<li>Once the box is assembled, glue the cleats in place.</li>
<li>Using a router with a 1/2" end mill cut the holes in the fan end plate. To accomplish this a template was made using scrap lumber and Kreg pocket screws. See photo.</li>
<li>Once the holes are cut in the fan plate, drill all the mounting holes.</li>
</ol><br />
<ol></ol><div>Construction photo set:</div><div><div class="separator" style="clear: both; text-align: center;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi3XH-onOSmU1MLq7GkoXvzmfdXeEWXn5LgW_GxOOFcMr5hb9yq92OzgwYKZE7gyRb346uMPbcHbtTIQiYSgDdj0vzCwPxVsqvLCxBHoXFCMZeNRENC5ikJfCXcy2hPlKfewcI2qXE5d8b/s1600/IMG_0009X.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi3XH-onOSmU1MLq7GkoXvzmfdXeEWXn5LgW_GxOOFcMr5hb9yq92OzgwYKZE7gyRb346uMPbcHbtTIQiYSgDdj0vzCwPxVsqvLCxBHoXFCMZeNRENC5ikJfCXcy2hPlKfewcI2qXE5d8b/s320/IMG_0009X.jpg" width="286" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Dayton 1TDR9 Blower</td></tr>
</tbody></table><br />
<div class="separator" style="clear: both; text-align: center;"></div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8OrnQUEccL2HzVU1QFMioO1fWb0Gyu4SPOSjGTQHcxJ8FyDkNDYNgUzSRFgR_Uc3MDR6N-9XOKKbcC3wqGsPGw5g6MC4YnysdqP1NJ0v2jhiA14ib-4iPyiBFfzA8V_7z6LnKO8qyWP6y/s1600/IMG_0023X.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="185" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8OrnQUEccL2HzVU1QFMioO1fWb0Gyu4SPOSjGTQHcxJ8FyDkNDYNgUzSRFgR_Uc3MDR6N-9XOKKbcC3wqGsPGw5g6MC4YnysdqP1NJ0v2jhiA14ib-4iPyiBFfzA8V_7z6LnKO8qyWP6y/s400/IMG_0023X.jpg" width="400" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Inside view of box side panel where lines indicate position of cleats.</td></tr>
</tbody></table><br />
<div class="separator" style="clear: both; text-align: center;"></div><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicdXCiq4QAaeYU-iWbHU4P9V-s3AwSYnzXNtDzmJnF-r51FaeDe2l-QbaN_mHxCjv_J8MklOS2SjIba68b1d9lj1wC4rhyQrVV7I1KIaAh_lDUgMQ-QQ-8Z2c0X5vvD0N2AvN78k84l6fQ/s1600/IMG_0026.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEicdXCiq4QAaeYU-iWbHU4P9V-s3AwSYnzXNtDzmJnF-r51FaeDe2l-QbaN_mHxCjv_J8MklOS2SjIba68b1d9lj1wC4rhyQrVV7I1KIaAh_lDUgMQ-QQ-8Z2c0X5vvD0N2AvN78k84l6fQ/s320/IMG_0026.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Jig for holding the box side in place. Wax paper on bench surface.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ3tiR3k2plEMod4VR7z1S-rmctKAqJjYmHRcVjRgXtIc3_H2s-BF3dm3V2UPKTKAmKlt24Wx3IiTQVywwP8oMRjT7aAE4jFNULTzIx-UaLgGvD8jcy9g15I8s6_Q892tOeOlcnCgxXkuk/s1600/IMG_0025.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiJ3tiR3k2plEMod4VR7z1S-rmctKAqJjYmHRcVjRgXtIc3_H2s-BF3dm3V2UPKTKAmKlt24Wx3IiTQVywwP8oMRjT7aAE4jFNULTzIx-UaLgGvD8jcy9g15I8s6_Q892tOeOlcnCgxXkuk/s320/IMG_0025.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Shows pocket screw for assembling and gluing sides.</td></tr>
</tbody></table><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Ixvk5EXV2mymPYYByBXTQ35M8ixt2ktOvdWAKsqztQGM6DzoUSc_EZN1qgFdbpqrADjOPh9tkuFaLAX5PBl9ZzNRD7ZSz7FtAdKp_AT93CGHtWz4r9xO3eyObz-ypHvTo-qzDIpB7CUJ/s1600/IMG_0027.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6Ixvk5EXV2mymPYYByBXTQ35M8ixt2ktOvdWAKsqztQGM6DzoUSc_EZN1qgFdbpqrADjOPh9tkuFaLAX5PBl9ZzNRD7ZSz7FtAdKp_AT93CGHtWz4r9xO3eyObz-ypHvTo-qzDIpB7CUJ/s320/IMG_0027.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Gluing filter cleats in place.</td></tr>
</tbody></table><br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdo5ySmXq7FXdeMTP9gLfFKtJ1FdnPv_ifmuwNIOE7VSoUioHg3PtxYPCrzfNyLmV3m4gBoRSFKS7leB2KWV74xE4EPckKbKcEd6YeRnLTmVvae0VBB-6Ai_IDlSLUhWCN44_fwOHXGywh/s1600/IMG_0029.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdo5ySmXq7FXdeMTP9gLfFKtJ1FdnPv_ifmuwNIOE7VSoUioHg3PtxYPCrzfNyLmV3m4gBoRSFKS7leB2KWV74xE4EPckKbKcEd6YeRnLTmVvae0VBB-6Ai_IDlSLUhWCN44_fwOHXGywh/s320/IMG_0029.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">Struts used to hold corner cleats in place during gluing.</td></tr>
</tbody></table></div><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmy2OeMwbl08GOPmXAC88wXrvYdU6mTRb02QpJM3VpUF_zVSifos7cFenSQw5wJH-NdmP3BBwhXEf51M4ByAUnka2RX05r5XmmxI9MPbPREJYEV8FOH4ajV9pkW7euUaEf2xZOaW11apE/s1600/IMG_0031.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhmy2OeMwbl08GOPmXAC88wXrvYdU6mTRb02QpJM3VpUF_zVSifos7cFenSQw5wJH-NdmP3BBwhXEf51M4ByAUnka2RX05r5XmmxI9MPbPREJYEV8FOH4ajV9pkW7euUaEf2xZOaW11apE/s320/IMG_0031.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Template for routing fan hole</td></tr>
</tbody></table><div><br />
<div style="text-align: center;"></div><div style="text-align: -webkit-auto;"><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG03Fl3CfbFCsJU95u_5VGwOjr6gMk5L32pyWqIwufyc2L62RAk6iMXQJaMMIm37GXridFzQ12FFiYKXsSLM3WiG16_wTa_ljtA2rTykF1kWQyT7IQZLdy29855cPrpNIwLKEiNCN75n0/s1600/IMG_0041.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjG03Fl3CfbFCsJU95u_5VGwOjr6gMk5L32pyWqIwufyc2L62RAk6iMXQJaMMIm37GXridFzQ12FFiYKXsSLM3WiG16_wTa_ljtA2rTykF1kWQyT7IQZLdy29855cPrpNIwLKEiNCN75n0/s320/IMG_0041.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Switch plate milled on Sherline</td></tr>
</tbody></table></div><div style="text-align: -webkit-auto;"><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1WrmWL-IKCv7mqGhlmr1S1nzDe3zezFEzMYDzRLcXlcdTfta6lwXATMulgoInO848JUCKaHtk0O1x1MZ1Q_mUb3E7IFvnHvHo8wkMotgmxBd6CSwOhjotz5O4_kabP4tYDxrk5Bglrf8/s1600/IMG_0043.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1WrmWL-IKCv7mqGhlmr1S1nzDe3zezFEzMYDzRLcXlcdTfta6lwXATMulgoInO848JUCKaHtk0O1x1MZ1Q_mUb3E7IFvnHvHo8wkMotgmxBd6CSwOhjotz5O4_kabP4tYDxrk5Bglrf8/s320/IMG_0043.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Fan and switch plate mounted and wired</td></tr>
</tbody></table><div style="text-align: right;"></div></div><div style="text-align: -webkit-auto;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFNsQP4yPnapVjVdQmKDG2kiWACdSArNDszbtdPVV0qdOovCO8C2cdzBr-WepAcHqDzU7K9lCOOVWCEv9nwaxiLKxYr7G-1rOqaEYN0bHxOsmzl8ngUU70bjVWbVwE4snVw2cPZWfsBeA/s1600/IMG_0047.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFNsQP4yPnapVjVdQmKDG2kiWACdSArNDszbtdPVV0qdOovCO8C2cdzBr-WepAcHqDzU7K9lCOOVWCEv9nwaxiLKxYr7G-1rOqaEYN0bHxOsmzl8ngUU70bjVWbVwE4snVw2cPZWfsBeA/s320/IMG_0047.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Fan mounted in box</td></tr>
</tbody></table><div style="text-align: -webkit-auto;"><br />
</div></div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com0tag:blogger.com,1999:blog-5047635659384377481.post-76095505756880686892011-09-14T19:24:00.003-07:002012-03-13T10:39:31.444-07:00Shop Wall Cabinets<div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;"></div>These cabinets are based on a design from Kreg which uses pocket screws and glue for assembly (<a href="https://www.kregtool.com/images/icons/wall_cabinet_1.pdf">www.kregtool.com/images/icons/wall_cabinet_1.pdf</a>). Since I like plastic pencil boxes for small parts and tools and plastic shoe boxes for larger parts, cabinet depths of 11 1/2" and 16" were used. For the shallower cabinet to fit between the shop windows a 29" width was used and since the wall studs in the shop are on 16" centers the remaining cabinets have a 32" width. The height of 32" was chosen so that two cabinets would fit on a 4' x 8' plywood sheet with the remainder of the sheet used for cleats and shelves. The plywood sheet was cut by HD into three pieces two being 32 1/2" in width, making car transportation easier.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxH691xKsfG1PIOQwPZv7GlhpiTBVWPQYw0CUAiAZEnEDXdYiueVfjuFjTat6Xgi_0sR4WZEpD8aEDmXp5sxcLXbmVWywrUab9jHa8SGQSdWecAS0OIl3yFmgKeSdGKHs2u7bzFwFhNcnE/s1600/IMG_0051.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxH691xKsfG1PIOQwPZv7GlhpiTBVWPQYw0CUAiAZEnEDXdYiueVfjuFjTat6Xgi_0sR4WZEpD8aEDmXp5sxcLXbmVWywrUab9jHa8SGQSdWecAS0OIl3yFmgKeSdGKHs2u7bzFwFhNcnE/s320/IMG_0051.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px; text-align: center;">First cabinet mounted between front windows.</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_dnVApm6XvBPii9Sbt_NvcvDXR2azrOFEhgbn6_g7D3aSbZlfdaX8ticfFWujX-f_GChrV_y1vdHGFAJUd1109MVoxQbI9jqWZb0bBxy1PGVABvj78qB7WhEUmnzJUh63xOWnF8rXzC0/s1600/IMG_0059.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_dnVApm6XvBPii9Sbt_NvcvDXR2azrOFEhgbn6_g7D3aSbZlfdaX8ticfFWujX-f_GChrV_y1vdHGFAJUd1109MVoxQbI9jqWZb0bBxy1PGVABvj78qB7WhEUmnzJUh63xOWnF8rXzC0/s320/IMG_0059.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Front of shop showing cabinets</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg7ciCq0oBNhugDXO6r1vTb_6znPA-3VWKP7OHBJH5UaWwr4BkFqQC1I3fFFXW8CI9xKrYhX-9_ygFdBITlADLxqtfJj7mSjcOnDYktVJ__9beJhYTXvmBPVr-zGD0q2OTK5lfOUJgDE4/s1600/IMG_0077.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgg7ciCq0oBNhugDXO6r1vTb_6znPA-3VWKP7OHBJH5UaWwr4BkFqQC1I3fFFXW8CI9xKrYhX-9_ygFdBITlADLxqtfJj7mSjcOnDYktVJ__9beJhYTXvmBPVr-zGD0q2OTK5lfOUJgDE4/s320/IMG_0077.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Large wall cabinets, 32" x 32" and 32" x 24"</td></tr>
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The basic structure of the cabinet is shown in the picture below. A rear view in the construction set below shows the pocket holes on the cleats. The other pocket holes in the design are on the top and bottom surfaces. The plywood used had one side clear and sanded and this surface was used on all visible areas such as the side exteriors.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwzG2gaaUbBXFaloXlgZJ-Db2RId2iNf6gU1kp7XS_ZPiAbaormhMN31KSQdUrnT7bPEx982j4LcOdcFPGibbB7eEXDG1ylKzuMyWNGlI2KfZ8QdttmExekWAM7slXFzTt4iP-cVb0-Ik/s1600/IMG_0050.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwzG2gaaUbBXFaloXlgZJ-Db2RId2iNf6gU1kp7XS_ZPiAbaormhMN31KSQdUrnT7bPEx982j4LcOdcFPGibbB7eEXDG1ylKzuMyWNGlI2KfZ8QdttmExekWAM7slXFzTt4iP-cVb0-Ik/s320/IMG_0050.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Cabinet basic structure</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: center;"></div>1/2" poplar cut to 3/4" width was used as front edging of the cabinet walls and attached with glue and brad nails. The backs are covered with 1/4" plywood and attached with 1/2" crown staples. Doors, which will be added later, will be made of 1/2" birch plywood and mounted with overlay partial wrap hinges.<br />
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When I started the project HD had just received special order cabinet grade 3/4" plywood for $28. a sheet. I bought one sheet and built a prototype 11 1/2" deep cabinet. The sheet turned out to be reasonable flat and had very few voids, so I bought four more sheets which should give me eight cabinets. I should have bought more, but I don't have the storage space. <br />
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<b>BOM</b><br />
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Small Cabinet:<br />
<ol><li>2 pieces 27 1/2" by 10 1/2", 3/4" plywood</li>
<li>2 pieces 32" by 10 1/2", 3/4" plywood</li>
<li>2 pieces 27 1/2" by 3 1/2", 3/4" poplar</li>
<li>1 piece 32" by 29", 1/4" plywood</li>
<li>2 pieces 29" by 3/4", poplar</li>
<li>2 pieces 30 1/2" by 3/4", poplar</li>
</ol>Large Cabinet:<br />
<ol><li>2 pieces 30 1/2" by 15 1/2", 3/4" plywood</li>
<li>2 pieces 32" by 15 1/2", 3/4" plywood</li>
<li>2 pieces 30 1/2" by 3 1/2", 3/4" poplar</li>
<li>1 piece 32" by 32", 1/4" plywood</li>
<li>2 pieces 32" by 3/4", poplar</li>
<li>2 pieces 30 1/2" by 3/4", poplar</li>
</ol><b>Step by Step Construction</b><br />
<div><ol></ol><div><ol><li>Make long cuts for sides, top and bottom 1/4" oversize, then trim to size</li>
<li>Use a table saw sled to cut ends to length, see sled project.</li>
<li>Drill pocket holes in top (above) and bottom (underneath) pieces. Holes not visible inside cabinet.</li>
<li>Screw and glue pieces together. Use squaring blocks while glue is setting.</li>
<li>Cut cleats to size and drill pocket holes</li>
<li>Screw and glue cleats in place</li>
<li>Cut 1/2" poplar to 3/4" width</li>
<li>Glue and nail poplar to front edge of cabinet.</li>
<li>Sand cabinet, including front edge</li>
<li>Round over all cabinet edges using a router and 1/8" round over bit</li>
<li>Sand all edges lightly</li>
<li>Seal all surfaces with Bulls Eye SealCoat</li>
<li>Drill holes for 1/4" shelf pins, I used Rockler jig.</li>
<li>Cut and nail back in place using 1/4" by 1/2" crown staples</li>
<li>Cut shelves from plywood, round over edges and sand</li>
<li>Paint surfaces if desired</li>
<li>Cut doors from 1/2" birch plywood</li>
</ol><br />
<ol></ol></div></div><div>Construction Photos</div><div><br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjdT1-2SfJw5b6g3WxmPA1vHqU4DIx0pkfXsRMs3A996uzCFymvzYOTgabXzorZCqunbEEjSNEUgdno6p8QrCaAtBISqNsZ07AYcTl8p4fAVocquRKUa7JdADOwRYNLVy06Gt5FLi31Kc/s1600/IMG_0058.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjdT1-2SfJw5b6g3WxmPA1vHqU4DIx0pkfXsRMs3A996uzCFymvzYOTgabXzorZCqunbEEjSNEUgdno6p8QrCaAtBISqNsZ07AYcTl8p4fAVocquRKUa7JdADOwRYNLVy06Gt5FLi31Kc/s320/IMG_0058.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Sled used to cut sides to length</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCsAEbYkA_c2uFBgCmiI3SKBBblvnyz4gpH4ix5EGBQP4EsbAwQi8xVg3SLPK4ET29En6-Bslu8JgF3GKLR4uKhTROe9uQuU3udHKd3PbKzMZ26-bqUE-D9aulQm2xchFC3AiRdhilQkk/s1600/IMG_0054.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCsAEbYkA_c2uFBgCmiI3SKBBblvnyz4gpH4ix5EGBQP4EsbAwQi8xVg3SLPK4ET29En6-Bslu8JgF3GKLR4uKhTROe9uQuU3udHKd3PbKzMZ26-bqUE-D9aulQm2xchFC3AiRdhilQkk/s320/IMG_0054.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Pocket holes drilled in top and bottom</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjWAR1uZG65eS6Uya1Mb8cBOGR4e5mF4_w1__Uw4oK4-NKB0bTGjw9vwjqFrDYD6fJmKE-JGtf5qN5TLx3ZSjeZSyD_2F7mDSRWOHEDNUYGSypqSTf8eGO3jNe4jpxePfnpjQXMCTO-mY/s1600/IMG_0055.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjWAR1uZG65eS6Uya1Mb8cBOGR4e5mF4_w1__Uw4oK4-NKB0bTGjw9vwjqFrDYD6fJmKE-JGtf5qN5TLx3ZSjeZSyD_2F7mDSRWOHEDNUYGSypqSTf8eGO3jNe4jpxePfnpjQXMCTO-mY/s320/IMG_0055.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Top being glued and screwed to side</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiW_ZoPrCrKvZMTKPQuXdxv_3yUocS7UaTNIH_Rz4Kjgh6kJz_oWBCkcoZNrv6Z-krMABM1isZO6I-346meY7vGwnLsIrOuR5J_417VhlOXvfUPfC4nZBnfgDhFrSJ5wi8OUxefY1chrg/s1600/IMG_0143.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiW_ZoPrCrKvZMTKPQuXdxv_3yUocS7UaTNIH_Rz4Kjgh6kJz_oWBCkcoZNrv6Z-krMABM1isZO6I-346meY7vGwnLsIrOuR5J_417VhlOXvfUPfC4nZBnfgDhFrSJ5wi8OUxefY1chrg/s320/IMG_0143.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Squaring blocks.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFDwHWa7NypmDDftKy9hI2DbJ9OLyDztL59PQc4Y2sUjiwI-fYfWFQKPrvZSbFi-0WNPlHz65pSeUKb-6atvuKrkHe_IXX413T_i_jLEmFrZog0-2e8J0QE0WznNO-9SuuixmdtwIlzIw/s1600/IMG_0053.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFDwHWa7NypmDDftKy9hI2DbJ9OLyDztL59PQc4Y2sUjiwI-fYfWFQKPrvZSbFi-0WNPlHz65pSeUKb-6atvuKrkHe_IXX413T_i_jLEmFrZog0-2e8J0QE0WznNO-9SuuixmdtwIlzIw/s320/IMG_0053.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back of cabinet showing top and bottom cleats</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFipnY749v-IgN3SMbXDWhrDJD8XSz4zPyx_aVfPmiE_7wWKnCRYTN-QTxVMKPufKOacUcdKErOsNDY8HANJkwxqM57-DTexSoNKgDt64L904jp4J-5ZJ7yY2eVxyBGLKDpbRfVcwTg4E/s1600/IMG_0101.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFipnY749v-IgN3SMbXDWhrDJD8XSz4zPyx_aVfPmiE_7wWKnCRYTN-QTxVMKPufKOacUcdKErOsNDY8HANJkwxqM57-DTexSoNKgDt64L904jp4J-5ZJ7yY2eVxyBGLKDpbRfVcwTg4E/s320/IMG_0101.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Heavy duty draws for wall cabinets.</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE9OdCmusrDokCTixyUs1fxf4C5ZTcNvxHIdWGrJi-oJYkz6rFxSBGF_wj2hl2es868o642FtwXVyqQtYkHGjqfyPCXHVB_fD6TUM91E-zy0XmduHUmmilAlqImsT7DwbSjAgJuhp21ac/s1600/IMG_0100.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgE9OdCmusrDokCTixyUs1fxf4C5ZTcNvxHIdWGrJi-oJYkz6rFxSBGF_wj2hl2es868o642FtwXVyqQtYkHGjqfyPCXHVB_fD6TUM91E-zy0XmduHUmmilAlqImsT7DwbSjAgJuhp21ac/s320/IMG_0100.JPG" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">One draw loaded with nails.</td></tr>
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</div>rinthesunhttp://www.blogger.com/profile/14214917278482595763noreply@blogger.com1