Cutting Diagram

%" PLYWOOD 48" x 48"

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  • Vix 5Vi" - 60" •Vi»" x 5Vi" ■ 60" <3Aö" x 5'/?" - 60" "/.»" x SVt" - 48"
  • V,»" x 7 Vi" - 48"
  • Vi»" x 7Va" ■ 60"

1 Vu" x 7 V* - 60"

  • Vix 5Vi" - 60" •Vi»" x 5Vi" ■ 60" <3Aö" x 5'/?" - 60" "/.»" x SVt" - 48"
  • V,»" x 7 Vi" - 48"
  • Vi»" x 7Va" ■ 60"

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the tongues. Next, tongues are cut to fit the grooves in the frame. These tongues are kind of a problem because they must be cut off-center. Since the wood for the frames is 13/W' thick and the plywood panel is only %" thick, I had to adjust the position of the tongues to compensate for this Vie" difference, see Details in Fig. 2.

To cut the tongues, I cut rabbets on both sides of the plywood, using a straight bit on the router table. It's best to test this cut on a scrap piece, slowly sneaking up on the depth of cut for each rabbet.

relief shoulder. Getting the face sides of the plywood and the frame perfectly flush is not easy (and usually more than I can manage). If the cuts for the top rabbet are off just a little, the plywood panel will be either too high or too low. Trying to sand the frame and the panel flush at this point is a problem because the face veneer of the plywood is so thin.

One trick to get around this problem is to rout a very small (Vi«" x Vi«") shoulder along the top edges of the plywood, see Details in Fig. 2. This small shoulder allows just enough relief so minor variations between the face of the plywood and the face of the frame are not noticeable.

  1. The last step before assembly is to cut a shallow rabbet on the four front and back pieces (B), see Detail in Fig. 2. This rabbet is used on the front of the case as a stop for the doors. And on the back of the case, it serves as a mounting joint for the frame and panel back.
  2. Now, both web frames can be glued and clamped together. Since the panel in the bottom frame is plywood, the tongues can (and should) be glued into the grooves.

CABINET SIDES

The two sides (0) of this cabinet are also cut from the walnut-veneer plywood. As shown in Fig. 1, I cut them 18" long (high). As for the width, I trimmed them a total of Vi" less than the front-to-back measurement of the web frames.

This width measurement allows for the Vs'-thick edging strips of solid wralnut on the front and back edges of the sides. (The top and bottom edges don't need edging strips because they'll be covered with the top and base.)

cut dado. The sides are joined to the web frames with a tongue and dado joint. First, I cut a dado at the top and bottom edges of both side pieces, see Fig. 4. Once again, I used the router table.

tongue on web frames. After the dadoes were cut, I cut two rabbets on the sides of the web frames, leaving a tongue to mate with the dado, see Fig. 4. (This can also be done on the router table — the same way as on the bottom panel.)

assembly. Finally, the sides can be glued and clamped to the two web frames.

FIGURE 1

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