Construct the frame

ICut the front and back frame members—rails (A and B), stiles (C), and mullions (D)—to the sizes listed in the Materials List. Note that the back frame does not have the two center mullions (D).

2 Cut the side frame members—stiles (E) and rails (F, G)—to size.

3 Lay out and cut the mortises and tenons in the frame members, where indicated on Drawings 1 and 2 above.

4 Glue and clamp the front frame together, checking for square, and adjusting if necessary. Repeat the procedure with the other frames. After the glue dries, scrape off the excess, and sand the joints smooth on both sides.

5 Fit your router with a rabbeting bit, and rout 'A" rabbets 'A" deep along the inside edges of all four frames, where shown on Drawing 3 on page 90. (We used a scrap of W oak plywood to check the depth.) Square the rounded corners with a chisel. The rabbets will later house the oak plywood panels.

%" tenon, 11 " long x 1V2" wide, centered on end


mortise, 4V2" long x 1 Vie" deep centered on edge

%" tenon, 1 " long x 4V2" wide, centered on end mortise, 4V2" long x 1 Vie" deep centered on edge


%" tenon, 1 " long x 4V2" wide, centered on end

6 Turn the frames over, and rout a lA" bead along the inside edges of all four frames, where shown on Drawing 3.

7 Install a dado blade in your tablesaw, and cut a W groove lA" deep 2'A" up from the bottom of each of the four frames for the chest bottom, where shown on Drawing 4, on page 90.

8Cut a 3A" rabbet 3/s" deep along each end of each frame, where shown on Drawing 3a.

9 Cut the side panels (H), the front panels (I), and the rear panel (J) to size from 'A" oak plywood. 1 /\To mark the veins on the front iVand side panels, first locate the vertical centerline on each panel. Next

0exploded view e3corner detail (lid)

W oak plywood rabbet W deep

Overall width 48'/2'

W cedar plywood-

Use brads and glue to - hold panels in place.

Vz" rabbets V21' deep

Square corners with a chisel after routing the rabbet.

3/s" rabbet 3/e" deep (all corners)

V2" groove^ I vi" deep

~Ve vein Vie" deep

Mitered corner

W cedar plywood e9 corner detail (chest)

W rabbet m deep

W oak and Va" cedar plywood, laminated rabbet - V2" deep

V2" rabbet V2" deep

Lid support

'A" oak quarter round

V'j" oak plywood Vl" cedar plywood

W rabbets Va" deep

V2" grooves Va" deep mark lines 3W' apart on each side of the centerline. Now, set up a straightedge, and rout three W veins V\(" deep in each panel. (See the Buying Guide for details about the router bit we used.)

UGlue panels H, I, and J in the rabbeted openings in the framework. Remove any glue squeeze-out on the face of the panels with a damp rag immediately after clamping.

To fashion the bottom, cut the oak plywood (K) and cedar plywood (L) to size plus Vi" on all sides. Then, laminate the two plywood pieces with contact cement. Finally, trim the laminated panel to finished size (163/i6x4515/i6") with a tablesaw or with a circular saw and a straightedge. (We cut our laminated panel W shorter in length and width than the dadoed opening to allow for contraction of the framework.) Dry-clamp the chest framework, making sure that the bottom (K/ L) doesn't prevent the rabbeted corner joints from fitting snugly. Once the framework fits together correctly, glue and clamp it, checking for square and making sure that the top edges of the four frames are flush.

M Scrape off the excess glue after it dries.Then, sand all surfaces smooth.

Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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