The Art of Woodworking - Cabinetmaking 1992

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THE ART OF WOODWORKING

HOMEWORI HOP



POWEROOLS

r Wear ppropriate afety ear: afetyglasses. ace shield or extra rotect n.and hearing rotectors rear plugs. fthere s ro dust ol ect on system. ea'dust mask. or xotic oods uch sebony, se respirator; he sawdust aycause n allergic eaction. ear orkg loves hen and l ing ough umber.

. Do not use ool f any part f t is wornor 0amageo.

. Keep our ands e away romturn ing l ade r b i t .

o l ) r a n o l h o n n ' r o r e o r d , n f a n n r r : h l c l n n l

over our hou er o prevent t fromgetting

n he way ndbe ng damaged.

SAFETYIPS. Concentrate n he ob; do not ush.Never ork when ou re ired, tressed rhave een r rnk ing lcoho rus ing

medrca t ionsha tduce

'ows iness .. Keep ourwork r ea lean nd idy;clutter an e ad o accidents, nd awdustand wood craps an be a i re hazard,

HANDOOLS

. Use l-eappropriateool or the ob:donot ry o make ool do something orwhich t was not designed.

. Clamp own workpieceo ee bothhands oran operation.

. Cutaway rom ourselfather ha n

toward our ody.

r f )n nnl fnr r o r lnn l tn i rpmnvino losq

mater al.or sharpen he cutting dge,

. Keep he d ges f cutting ools harp.

ANATOMY F A BOARD

WORKSHOPUIDE

Aleo knovrn e band c lamp oreLrap l a rnp : lyp ica ly va iab lewith eLra2 15 eeL. n enqLh. orapp ly tnq?re .aL) r. n more Lhano - P ) . p r t i o n , - , . c \ ) . e c * ? - o

four cha i r eqe L once .

CABINETMAKINGLAMPS

Quick-actionc t a m ?h 6 0 K n o w n 5

cab ineLmaker.ec a m ? : y ? c a yiae a 2 / lh roa l AepLh nb ,a 4 - inche2an , uL ao ava i b letn a rqer i zee .

with deep LhroaLe orex lend ,ed am2inq each

? i p e o lampSuiLable orc l a m ? r n q n I e rL h a n 2 n c h e e .Cone ie le f awe a l*"ached lo

. o . / . _ c r _ a r a 1 f i , -? ? " ,

p ige enq th can be cu .Lorn tzeato f i l a parLicu r . ?an ,

Spr inq c lampAvai ab le n a var ie lyc:feizes or ci.am.ptnqu2 C 4 nc l , e" ' ' . o rnemode . have ? aglic t.t?.Lc,t rolecL atock.

Double - s ided lampane Eil,e f clanp eecure"votNorL urface anA cLheeiAe r: etr:ck; ealureereach of tp to 5a incheadepenAinq n he rYod ,

6 a r c l a m pC amge uV u A fuelin enq lh ava t b le ' ,more ornmon tzeea r e 2 4 , 3 6 a n d48 nchea .

Tr iqger l ampAvai lab le n epaneo f 6 , 1 2 , 8 , 2 4 a n d36 inchee : ee i4neAl o b e neLal led nd

removeA tiLh nehand . TadAedlaweproLecL tock,

Handecrewf, ao Kncwn a acrewclamp. Comee nvar io l s e izee wi"vhjawe haL can o?enu p o 1 6 n c h e e i d e ,

Web c lamp



THEARTOFWOODWORKING

CABINETAAAKING



THE ART OF WOODWORKING

CABINEMKING

TIME-LIFEOOKSALEXANDRIA.IRGINIA

ST. REMYPRESSMONTREAL. EWYORK



THE ART OF WOODWORKING was produced byST.REMYPRESS

PUBLISHERPRXSIDENT

Series ditorSeries rt Director

SeniorEditors

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Research ditorPicture Editor

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Kenneth WinchesterPierre Ldveill6

Pierre Home-DouglasFrancine LemieuxMarc Cassini Text)Heather Mills (Research)Normand Boudreault, Solange abergeLuc GermainTimMcRaeChristopher acksonTamsin M. Douglas, Andrew onesStephen HartRonald Durepos, Robert Paquet,Studio La Perludte nc.Natalie WatanabeMichelle Turbidefean-Luc RoyRobert ChartierChristine M. JacobsIudith Yelon

THECONSUXTANTS

Mark Duginske, a cabinetmaker ho livesin Wausau, Wisconsin, is a contributingeditor to F n e W oodwo king magazineand he author ofseveral books on woodwork-ing power ools.

Leonard Lee s the president fVeritas Toolsand Lee ValleyTooli, manufacturers nd retail-ers of fine woodworking hand tools. He s alsothe publisher and executive ditor of Woodcuts,a magazine hat focuses n the history andtechniques f woodworking.

Giles Miller-Mead has aught advanced abi-netmaking at Montreal echnical schools or

more han ten years. A native of New Zealand,he previously worked as a restorer ofantiquefurniture.

foseph Truini is Senior Editor ofFlomeMechanixmagazine. former Shop and ToolsEdrtor of Popular Mechanics, e has worked asa cabinetmaker, ome mprovement contractorand carpenter.

Cabinetmakingp. cm.-(The Art of Woodworking)

Includes ndex.ISBN0-8094-9904-5. trade)

ISBN0-8094-9905-3 lib)l. Cabinetwork.L Time- Life Books. II. SeriesTTt97.C2r2 1992684' .04-dc20 92-11188

CI P

For nformation about any Time-Life book,please all l-800-621-7026, r write:Reader nformationTime-Life Customer ServiceP.O.BoxC-32068Richmond, Virginia2326r-2068

@ 1992 ime-Life Books nc,All rights reserved.No part of this book may be reproduced nany orm or by any electronic or mechanicalmeans, ncluding nformation storage ndretrieval devices r systems, ithout priorwritten permission rom the publisher, exceptthat brief passages ay be quoted or reviews.First printing. Printed n U.S.A.Published imultaneously n Canada.

TIME-LIFE s a trademark of Time WarnerInc. U.S.A.

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THE TIME INC. BOOK COMPANY

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Associate ublisherMarketing Director

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Mary N. DavisRobert H. SmithThomas H. FlahertyEliseD. Ritter-Clough

Trevor LunnRegina HallDonia Ann SteeleBob DoyleMarlene Zack



CONTENTS

6 INTRODUCTION

12 CABINETMAKINGTECHNIQUES

16 CARCASECONSTRUCTION18 Anatomy of a carcase20 Making wide panels27 Carcase oinery39 Edgebanding

4L ShelvingFRAME-AND.PANELCONSTRUCTIONAnatomy of a frame-and-panelassemblvMaking the frameMaking the panelPuttinq he panel n the frameAssembling frame-and-panelcaseInstallinga bottom panelShelvingInstalling a topInstalling molding

44

46

48535759

606 T6469

r00 DooRSI02 Anatomy of a door104 Frame-and-panel oors108 Solid-panel oors111 Glass oors113 Veneered-panel oors115 Hanging a door

I2O LEGSL22 Anatomy of a cabriole eg

L24 Cabriole egsI28 Thpered nd octagonal egs131 Inlays and detailingI33 Leg oinery

I4O GLOSSARY

I42 INDEX

IM ACKNOWLEDGMENTS

72 DRAWERS74 Anatomy of a drawer76 Drawer oinery

85 Assembling drawer87 Mounting a drawer95 Drawer stops97 False ronts and hardware





INTRODUCTION

Ian Ingersoll n building a

SHAKERCHESTf remember hen firstcame nder he spell f Shakerurniture.Wandering heI ha[s of the Shaker useum n Old Chatham, ewYork, was ransported oanother ime,awestruck t he eeling voked y hose imple ieces. heShakers erea religious, topian ocietyhat lourished n New England nd_the idrvestn the19thCentury. heir urniture esigns ere orn at east artially ut of a desire o

lead simpler, ore eligious xistence.n theirquest,

heyachieved purityof design

rivaled nlybythe workcreated or he Buddhistemples f|apan'_For ack of a more escriptiveerm, have ubbed hecupboard ndcase f drawers

shown ere TheUtilityChest."tsprototype, hose riginal urpose s no-longerknown,was uilt n Enfield, onnecticut, round 825-1850.hesurprising ff-centerplacement f the wosmall rawers emonstrates haker esign t tsheight, gp$gnot only o a purityofform,but to the asymmetry fhuman existence swell.Theoriginaiunction fthose wodrawers aybe ost oday, ut t is sure o have eena practical ne.

Theutilitychest sbuiltofpineandmeasures 7 nches eep, 1 nches ide and71 nches igh. ts constructions relatively imple ndcanbe accomplishedsinga combination f standard asework-, oor-and drawer-makingechniques. ora

project ike his, however, ttentionhould epaid o the ayout_ofhe design. find

it trilpm to do a ull-scale rawing n either arge iece f cardboard r the rahlysanded op of myworkbench o ensure hat he scales correct.

Finishinghispiece as considerable hallenge. ostcabinetmakers renot in-ishers. t should epointed ut hat he rick o any good inish s o build t up grad-uallywithmultiplehincoats.n this case, ightyellow aintlvas sed irst, hen steelwool, ollowed ya wash f pumpkin aint,more teel ool,and an application forange hellaco warm up he yellow. he inishing ouch omes itha ight coatingofvarnish r acquer o protect he shellac.

lan Ingersoll wns a cabinetmakingshop n WestCornwall,Connecticut,sp cializing n Shaker urniture.





INTRODUCTION

MichaelBurns alks about

CRAFTSMANSHIPhe nspiration or hiscabinet ame roma small illet of Swiss ear iven omeseven ears go. felt hat t had aken meat east hat ong o acquire heskills

toworkwith hisbeautiful, utsomewhat ifficultwood. he pearwas dark goldenpinkandhada soft appearance. designedhecabinet o highlight hewood's on-derfi.rl urface nd ts ability o stand p o the shaping f delicate dge rofiles.want-

ed o show ffthe awmaterial.I resawedhepear ntoveneers, scnt %-inch hick,bookmatchedhem, nd gluedthem o a plywood ore. thenedge anded nd shaped he op andbottom. doweledthesideso small Ya-inch osts, eeding olidwood or he ointswith he egs. ext,I doweled he op, bottomand sides ogether recisely,sing ne dowel er nch.finished ll he pieces efore luing p.The egs,made rom arrah,were hennotched,glued ndscrewedo the corners fthe cabinet.

Pear sas emanding s t isbeautiful. he oinerymust e ightandperfect; lightimperfectionsre erynoticeable.spent great eal f ime sharpening yplanesto get heedgeoints risp nd he surfaces nflawed. he arrah, n he other and,was pleasureoworkwith. t planed n anydirection, awed ndshaped asily,ndtook he ightoil inish applied erywell. finished he pearwithseveralhin coats

of blondshellac, ringing ut ts colorandsurface arkings.Inside hecabinet re wo drawers, achmade f Andaman adauk nd amphor.Under hedrawers,n the middle f he nterior, sa curved helf. made heL-shapedknifehinges nd doorpulls rompatinated rass.

My nspiration omesromseveral ources,ncludingmy eacher imKrenov, reekarchitecture,apanese raft ndFrench abinetmaker mileRutrlmann. hat s mpor-tant n everythingmake s hat he nfluences re alanced,hecraftsmanships hebest can achieve, nd he esults leasing.

MichaelBurns eaches abinetmak-ing at College f the RedwoodsnFort Bragg,Califurnia.





INTRODUCTION

Terry Moore and his

WRITINGDESKeing elf-taught, relyon avery nformal pproach o design. y urniture endsto evolve s proceed hrough he construction rocess. orexample, eeking

an alternativeo the common apered eg,and nspired y 1920s abinetmakersuleskleu andEmileRuhlmann, developed multifacetedluted eg.Todo his, designeda ixture or my spindle haper hat allowedme o profileand lute he welve acets

of the eg.Aftermuch rial and error, had oneprototype egand a whole newchal-lenge:Namely, ow o attach he eg o a table or desk apron.Eventually, made amock-up f a desk with a diagonal orner ostand attached he eg o the post.Presentinghe egat a 45o ngle roduced isually leasing etailshatbecame heinspirationor his ady's riting desk.

Toconstruct he desk, used combination f mortise-and-tenon nddovetailjoinery. hedrawers realso ovetailed. chose ubinga-African osewood-whichis emarkable or ts strikingigure nd color. hegrainpattern n the desk opwasachieved yresawing plank nto %o-inch-thick eneer. wonderful treak f ight-colored apwood races needge f he plank.When he sapwood dges ere luedtogether nto bookmatched mirror mage) anels, he results ere pectacular.Around he perimeter f the op and where hesurrounding ramemeets hepanels,

I inlaida hin ine of curlymaple o add isual exture nd o emphasize he rame-and-panel ffea.Adding urlymaple ullsanda cockbead round hedrawersurtherenhanced hecolorcontrast. llthese eatures ork ogether o evoke sense f func-tionalelegance.

While hisdesk sobviously mmplex iece, oushould ot eel ntimidated; verycraftsman as nce novice. ou an, with he ight nstructional nformation, longwithpatience ndpractice, aster ll of the echniques hatyouwill need.Remember,though, hemuseums anwait o enshrine ourmasterpiece,odon'tbiteoffmorethan oucan hew ightaway. tart with simple rojectshat allow ou o practiseyourskills nddevelop ourdesign ense. simple rojectwellexecuteds ar betterthanan elaborate iecehathas een hoddily ade. here ill be ailures nd mis-takes long heway, ut his, oo, spart of he process f earning. he mainobjective

is o enjoyyour orkanddo he best oucan.

Originally romWales, TerryMooredesigns nd builds ine urniture nNewp rt, NewHamp hire..



CABINETMAKINGTECHNIOUE-l- h. first step n any cabinetmakingI. project s o select nd prepare our

stock.As shown below not all he woodat a umberyard s free of defects, o tis mportant o choose oards arefully.

Whether ou are buildingan armoireor a toy box, most stock s readied n

CHO()SINGUMBER

roughly he same way.The proceduresillustrated n pages 3 to 15 cover he

basic echniques. or rough, or unsur-faced umbet first pass ne ace acrossthe ointer, hen one edge, roducingtwo surfaces hat are at 90o o each th-er. Next,plane he second ace,making

it parallelo he irst.Now ou are to rip your stock o widthand croit to ength. ordressed, r surfaceber, ouonlyhave o ointoneedgeripand rosscut. efore luing paof urniture, esure o sand ny uthatwillbedifficulto reach fterw

COMMON OOD EFECTS

Knot, CheakA dark whorlaurcounded y newqrowth ringe; may fall out, affect-inq appearance. Avoid eawing

9plito acroae qrowDhringa, affectinqapPearance

through thia defect.

Pitah

CrookEnd-to-end curvealon4 edge

Kesinaccumulation naurface; can affect

TwiatUneven r irceqular warping;makea board unatable andprone to further warpinq

SelectingtockorcabinetmakingWood s avarlablen wobroad ategories: ardwoodnd oftwood.Althoughhe erms rebotanicalather han escriptive, ard-woods, uch s mahogany nd herry, repreferableor mostcabinetmakingrojects ecausehey re, n act , enerallyharder. efore uyingumber, xaminet carefully.hecktscolor,exture ndgrain atterns, nd elect tockhat ou indvisual lyppealing.umbers usual ly i l led none f wo ways:

Quarter-sawed,redge-grainedumber as ough urfaceisgenerallytable; lain-sawed,r lat-grainedumber, l thless xpensive,s more roneo warping nd hrinking. hatype f wood oubuy, hoose iln-driedumber, ndwatchfordefects. ome f hose hown bove nly ffect ppearbutothers anmake he wood ifficulto cut, oint r plaYou an void efects ybuyingselect"lumber hen ossi

t 2



CABINETMAKING TECHNIQUES

JOINTINGBOARDMaintainingroper ressureon he outfeedableFormost perations, eta cutting epthbetween a nd ru nch. o ointa boardedge, eed he stock lowlynto he cut-terhead, ressingts ace gainsthe encewhi le eepingheedge aton he ointertables. e sure o eed he workpieceothe kn ives r e u t t ing i th he gra in .Con t inuee e d i n gh e s tock n t i l ou rright and pproaches he outfeed able.Then everse he position fyour andswithout toppinghe ut . Gradual lyl ideyour efthand oward he back f heworkpiece, aintai ng pressure gainstthe ence /eff) . hift our ight andfar ther ack n he stock o mainta indownwardressureust o he outfeedside f he knives . ont inuehese and-over-hand ovementsnt i l he oass scompleted. o oint he ace f a board,fol lowhe same rocedures ,s ing ushblockso eed he stock.

Feedinghe workpiecento he cutterheadSet cutt ing epth p o %e nch. tandto one ide f he workp iecen du seboth ands o eed t careful lynto hemachine, eepinghe edges f hestocko a r a l l e lo h e p l a n e rab le . nce hemachine r ips he board nd beginspullingt across he cutterhead,upportits railing nd o keep t flaton he able(left). henmove o the outfeed ide ofthe planer. uppor theworkpiecei thboth ands nt i l t c lears he outfeedrol ler. oprevent tock om warping,avoid ass ing nly ne ace f a boardthroughhe machine;nstead, lane hesame mount f wood romboth ides.

PLANINGTOCK

1 3



RIPPING W()RKPIECE

Usinghe ip ence s aguide

Set he blade eight boul /qinchtheworkpiece.ositionhe ip ence owid th fcu t , hen ush he tock nthe blade, ressingt againsthe ewith our efthand nd eeding iththumbs /eff) . tand o one ide fworkpiecend traddlehe enceyour ight and, aking ure hatnehand s n inewith he blade. eeo uing he board nti l he blade uts hroi t completely.okeep our ands

coming lose rhan inches romblade, ompletehe ut with push(Caution: lade uard artially etrforclarity.)

CR()SSCUTTINGTOCK

Usinghemiterauge

With he workpieceush gainst hemiter auge, l ignhe utt ing ark i ththe b lade . os i t ionhe i o ence e l laway rom heend f he stock o pre-vent he ut-off iecerom amming pa g a i n s th e b l a d e n d i c k i n g a c ktoward ou.Hookhe humbs f bothhands verhe miter augeo hold hestock rmly gainsthegauge nd aton he able, hen eed he board ntothe blade righil. Caution: lade uard

partiallyetracted or clarity.)

CABINETMAKINGTECHNIQUES

t 4



CABINETMAKINGTECHNIQUES

SANDING

Using sanding lockClamp top locks o a work urface t both nds f heworkpieceo hold t s teady. i ta sanding lock i th pieceofabras ive aper nd and hesurface f he stock longthe grain , pplyingven,moderate ressureabovd. selong, mooth, ver lappingtrokes nt i l he urfaces smooth.Repeat i th a finer-grit aper ora smoother inish . o pre-vent oundinghe edges f heworkpiece ,eep he sandingblocklaton ts surface, ndwork p o-but not over-the dge.

THE ELT ANDERSPTANER

Using belt anderUse s top lock o keep heworkpiecerommoving.ns ta l la sanding el t nd rape he power ord ver our houlderto keep t outof he way.With he sander arallelo he woodgrain ,urn tonand lowlyowert onto he urface , oldingit firmlywithboth ands above). ovehe machine ack ndforthwith he same ype f strokes ouwould sewith sandingblock. o avoid ouginghesurface, eep he sander latandalways oving; onot et he machineest n spp nnt

Smoothingpanellfa planers notavai lableo even utthe surface fglued-up anels, se beltsander. he iagrams n he eft llustratethe correct equence foperations.irst,s lowly ove he sander ack nd or thacross he surface l a 45 'angle othe wood rain far eft),Besure o covertheent i re urface, utdo not e t he andingdrum uncompletelyff heedges f hepanel ;h ismay ound he corners . ext,make second ass ack nd or thdiagonal lycrosshe grain n he oppo-sitedirectioncenter efil.Finally,unthe ool long he wood rain o removeany c ra tchese f tb y h e e a r l i e r a n d -ing (near eft).

\

l 5





Usingbiscuit oints to assemble anels offers wo veryappealingbenefits: trength nd ease f assembly. biscuitjoiner cuts emicircular roovesnto matingpanek. Theslots re illed with glue and biscuits of compressed eech,then he panels are butted ogether o orm a perfea oint.

CARCASE,ONSTRUCTIONhe basic ox-or arcase-fea-tured in this chapter has ong

been he starting oint of manytypes of furniture. The earliestexamples ere imple offers, ailed

or peggedogether,hatserved ou-ble-duty s hests r benches. oduy,thereare seeminglyimitless aria-tionson hat same asic esign. hesmallest xamples f carcase on-struction eature elicate ieces fhighly igured,exoticwoods, uchas bird's-eye aple, osewood rHawaiian oa, hat are assembledwith precise oints and delicatehinges o form ewelry oxes nd silver hests. arger ut stillcompact oxes rovide he ramework or drawers.

Once ssembled, he ypeof carcase xaminedn the pagesthat ollowcanbe he basis or anything rom a small dresseror tool chest o a floor-to-ceilingabinet r a home-enter-tainment enter. he ater chapters n this book ook at hesubsequent teps-adding rawers, oors r legs-so as oturn the basic arcase nto a inished iece ffurniture.

Althoughcarcases nddrawers re designed o withstanddifferent ypes nd evels fstress n use, here re certain on-struction echniqueshat areapplicableo both. Where ppro-priate, cross-referenceo the Drawers hapter ill be ncludedto direct ou o a drawer-building echnique hat couldproveusefi.rlor constructing arcases.

All carcases onsist f four panels oined ogether o forma box. A key equirement s that he woodgrain of all the

Drawers, helves nd aveneered lywoodbackpanel transform a typical carcase nto anelegant ookcase. he drawers un along ixedshelves et nto dadoes ut n the side anels.

assemblinghepanels. here re agreatmanytypes f cornerjoints oucanuse; ome f he most ommon nclude ovetails,

lockmiters, abbets, iter-and-spline oins, biscuitoints,andboxand inger oints.Because ovetailointsare ighly egardedfor their strength nd beauty n solidwood,onevariety-thehand-cut hrough dovetail-is featured n this chapter page27).It canalso ecutmorequicklywitha igasshown n theDrawers hapter page 0).In he eyes f manywoodworkers,awell-made and-cut ovetailoint svisible roofof the cab-inetmaker's ompetence.

Forplywood arcases,abbet page 4)orbiscuitoints-alsoknownasplate onts-(page 6) arebetter hoices. oth offerpretfymuch hesame trength sdovetailointsand,althoughless sthetically leasing,heyarequickand easymethods f

assembly. heconvenienceactor ecomes major onsider-ation f youare aced ith producing arge umber f carcases.

panels un in the same irection.Since oodexpands ndcontracts,especially crosshe grain, hepan-elswill expand nd contract ogeth-er at the same ate, reservinghe

structural ntegrity of the box.Assembling carcase ith hegrainofadjacent anels t right angles oeach ther irtually nsures hatoneof the panels ill eventually plit;whenwood s ready o move, t isalmost mpossible o stop.

Muchofthe character nd ndi-vidualityof a particular carcasedesign erives rom he method f

1 7



hether t is a box hat will housea couple f drawers nda shelf r

ment s that parallel anels musthavethesame imensions.

Although panel anbe made roma single iece f umber, t is generally

less xpensiveo gluenarrower oardsedge-to-edgeo form he widesurface(page 0).Once lued p, he panels replaned, ointedon one edge, ut o size,

funelUaed o form the top, bottom andsidea of the carcaai, May be a ein-6le piece of plywood or eolid lumbenbut panela are more commonly madefrom amaller boarda qlued edqe oedge; dowela may be ueed to helpwith alignment. ndividual boardscan be of varyinq widtha, but areuaually 2 to 5 inches wide.

and hen heirsurfaces resandethird option-one whichcombineeconomy fglued-up anels ndease f solid umber-is to use hwoodplywood, hichcanbe madlooklike olidwood,ytheadditiobanding long xposed dges pageConstructing arcases rom plyw

a china abinet estined o grace ourdining oom, he carcase oubuildwill

featuremanyofthe basic lements llus-trated elow. irst, t will haveoursides,or panels, hichare usually he samewidthand hickness. nother equire-

CornerjointSecurea he ende of thepanele ogether: rabbetjoint ia ahown, but dovetailand plate ointa are aleopopular choicea.

This simple carcase-framed abinetfeatures edge-glued aneh of ash andrabbeted ornerointscuton a table aw.Afixed upper shelf s set n dadoes utinto he side anek; loweradjustable

shelfrests n hidden supports.

BackUaually /+-inchplywoodpiece nailedand'glued ntoa rabbot routed alonq baoked1e of the panela.

thelvingMay be plywood or ein7lepieae of wood, but often madefrom edge-qlued boarda. Fixedahelvea are qlued n dadoesrouted on the inside surfacesof aide panele; adjuatableehelvea egt on aupporta.



does ave ts disadvantages, owever.It reduces our lexibiliwwhen t comesto the oinery; ovetaiis,or example,simplywillnot work. t also ules out

such sthetic ossibilitiesscreatingattractive rainpatterns n thepanels yedge luing areflrlly

matchedboards.

CARCASE ONSTRUCTION

Ifyou plan o add edge anding rinstall helvespage 1 , youmust ntic-ipate hose teps efore luinghepanelstogether. orshelves, ou will need o

routdadoes r boredowel oles n heinside urfaces fthe side anels.Formoredetail n he cutting,oint-

ing, sanding nd other procedures

necesssaryo prepare oards nd panels,refer o the Cabinetmaking echniquessection npage 2. Of he many oinerymethods hatcanbeused o connect he

panels fa carcase,hischapter ocuseson three of the most common: hehand-cut hrough ovetail oint, heplate oint and he abbet oint.

CORl{EROINTS

Through dovetail ointTapered ine on one panel nterlock withanqled aila of the other: offera lar1e

qluing aurface. For best appearance,pino are ueually cut at the enda ofthe top and bottom panela; aileare aawn at.enda ofthe eide panele.Stronq, decorative oint for eolid lum'ber; not recommended or plywood.Good choice when eaturinq oineryae an element of deoiqn.

Plate or biocuit ointDiecuits of compreaaed wood itinto slote in the matinq boarda;qlue owello he biacuite, atrength'eninq he joint. To conceal end1rain when viewed rom the aideof carcaae, alots are uaually cutinto end 6rain of top and bottompanela and into mating facea ofoide panele, tronq joint for aolid

lumber or plywood.Not decorativebut quick and eaay to make.

Rabbet ointEdge of one board fita into rabbetcut in the matinq board; offerslarqe gluinq aurface. To concealend grain of top and bottompanele, he rabbeta are normallycut into the aide panela. trongjoint for aolid lumber or plywood.Alao uaed o join carcaee backto panela. Not ae decorative aa

a throuqh dovetail, but muchaimpler o make.

J .' v#' ' ' o S

r #' d

Edge bandingDecorative veneer commercially available butcan be made n the ahop; glued o expoeededqeo of plywoodpanela and shelvea.

I 9



MAKINGWIDE PANELS

\ 7f ost woodworkers ake up theIVJ. widepanels or a carcase ygluingboards ogether dge-to-edge. uildinga carcase hisway s not a matter f cut-

ting costs t the expense f strength.Panels fedge-glued oards re every itas strong s a single iece f umber. nfact,a proper glue oint provides sturdierbond han he ibers fa oiece fwood.

Follow he steos etailed elow ndon he ollowing ages o assemble an-els.Apart rom a supply f glueand an

assortment f clamps, ll you need s alevelwork surface r a shop-built luerack page 4).To help keep he boardsaligned, omewoodworkers lsous e

dowels page S).Formore nformationon selecting lue, efer o the nside ackcover fthis book.

Selecting our wood s an mportantpart ofthe process. o not buy greenwood or stock hat s cupped r ftvisted,and avoidusingwood with a high mois-ture content, hich can adversely ffect

the glue. nstead, uy umber hatbeen ried n a kiln. f you are worfrom rough stock, begin preparboards y ointing a face nd an ed

then planing he other ace. ext, rcut he boards, eaving hem oughinch onger han heir inished enandjoint an edge feach iece. ipstock o hat he combined idth othe boards xceeds he finished wofthe panel y about inch, henthe cut edses.

Edge-glued boards should create heillusion of a single piece of wood rather

than a composite. xperiment with theboards n diferent configtrations oproduce a pattern that is visually nter-esting but make sure hat thegrain runsin the same direction on all of the oieces.

EDGELUING' l Arranginghe boardsI Set wobar lamps n a work urfaceand ay he boards n hem. se s manyclamps snecessaryo supporthe boardsat 24- o 36-inch ntervals,o eeo he barsfrommoving, lace hem n notched oo dblocksinsef). se pencilo mark he en dgrain rientationfeach oard sshown,then rrange he stock n he clampsoenhance heirappearance photo bove).

Tominimize arping, rrangehe pieces othat he end rain fadjacent oardsuns nopposite irections.f hegrain s diff icul tto read, ampen rsand he board nds omake t show p more efinitely.nce ouhave satisfactoryrrangement,lignhestock dge-to-edgend se pencil rchalkto mark riangleright).hiswillhelp oucorrectlyearrangehe boards fyoumovethem rioro inal ssembly.

20



CARCASECONSTRUCTION

fillllllll]lllllll lllllllllillllllllllllil llllllllllll1HO? TI?Two wayo toopread glueTo soread a alue bead

art oupply lores .To leanlhe

rollerafler use, oll I repeaNedly

r) ApplyingheglueL fo auoid arringhe edges f hepanel hen ou ightenhe lamPs,cut wopieces fscrap ood t east

as ong s he boardso be glued, nduse hem s pads . eavinghe irstboard ace own, tand he otherpieces nedge o hat he r ianglemarks ace way rom ou.APPIYa hingluebead o each oard /eff),justenougho coverhe edge om-ple te ly hen he adhesives spread.Too itt le luewil l esul tn a weakbond;oomuch i l l ause messwhen ou ightenhe lamPs. sesmall , t tff-brist ledrusho spread

theglue venlyn he board dges(abovd, leavingobare Pots. onotuse our ingersorsPreading;adding irtorgreaseo hegluewil lweakenhe bond nd low he dryingtime.Move n o step as soon spossibleo preventheglue rom ry-ingbefore ou ightenhe lamPs.

overa ocrap board. For a ohoP-madealue preaAer, ee a 6- inch enqlh fi/"-inchdowel e a handleNoholda2-incheection of a broken r wornhackeaw lade. se a backeaw rband saw NocuN shallow lot' n oneend of lhe dowel,makinq t' 'hinenouqhlo holdNhe ladeeection onu4ly. iI th ebladeNeelh-eide-ouLnt'o he sloL'



CARCASE ONSTRUCTION

Tighteninghe lampsSet he boards ace down nd ine

u p h e i r n d s ,m a k i n g u r e h a t h es ides f he r iangle l ign. ightenhec lamps nder he boards ust enoughto but t hem ogether, heck ing ga inf o r a l i g n m e n t . v o i d v e r t i g h t e n i nthe c lamps r he boards ay buck leup a t he oints .Place thirdc lampacross he op of the boards, enteringi t be tween he wo undernea th . in i sht i g h t e n i n g l lo f t h e c l a m p s n u r n(left) until here are no gaps betweent h e b o a r d s n d a t h i n b e a d fg l u esqueezes u t of he oints .

LevelingheboardsForadjacent oards hat do not ie

perfectlyevel ith ach ther, seC c lamp o ho ld hem n a l ignment .Protectinghe boards i th wood ads,cen te rhe l amp n he o in t ea r heend f hestock; lace strip fwaxpaper nder ach ad o preventt romstickingo he boards. hen ightenheclamp ntilhe boards re evel right).Refero he manufacturer'snstructionsfor heglue's ryingime. fyou re hortofclamps, ark he ime n he panelso hat ou anmove n o he gluingof he next anel ssoon spossible .



CARCASE ONSTRUCTION

f, Removingheexcess lue:,f Use plastic utty nife o removeas much f he squeezed-outlue sooss ible eforet dr ies . hemoisture

f omg l u e ef to n h e sur face i l lb eabsorbed y hewood, ausing wellinga n d l o w r y i n g ; a r d e n e d d h e s i v ec a n l s o l o g andpaper,u l lp l a n e rknives nd epel ood ta in . nce heglue as r ied , emovehe lamps romthe op of he boards, nduse paintscrapero remove ny queeze-outha tremarns/eftl.Removehe ower lamps,then preparehe panel or oinery yplaningt, o int ingnedge nd ut t ingthe p i e c eo t s n i shed imens ions .

Use belt ander o smooth he sur-faces hat wi l lbe hard o each ncethe carcases assembled

"llllflt"llJ"llflll$ "lfif"1lr1llf".llr'ffillll"l$1HO? TI??revenlingclamp otainsThe metal bar of a clampcan be olained by adheeivethal dr ipo dur in4 luing

operationo. ried luecanaleo ntertere with Iheratchetinq action oteome lamoe.To l imi-nat'eNhe roblem, se ahaoksaw r band eaw o cuta rollof wax ?a?er nto Z-inch'widemini ' ro l ls .Then,achNimeyou applya clamp,tear ofl a ot'ripof paVer o wrap overor under Nhebar.

23



CARCASECONSTRUCTION

GIUE ACKA shop-builtackmade rom wosawhorses rovides convenientway o hold he clamps orgluingup a panel. obuild he ig, emovethe cross iece romyour awhorses.Cut eplacementshe same idthand hickness s he originals, akingthem t east s ong s he boardsthat ouwillbe gluing.

Use hand aw ra band aw ocut notches

long needge f eachcross iece t 6-inch ntervals. ak ethe cutswide nougho hold barc lamp nugly nddeep nough ohold he bar evel ith he op of hecross iece. ou analso ut notchesto accommodate ipe lamps, utbar lamps re tronger.

Touse he glue ack, eat t easttwobar clamps n he notches othat he boards o be glued resupported t least very 4 to 36

inches. he est f he operationsidenticalo edge luing oards nawork urface sshown n steps to5 on he preceding ages.

L A



CARCASECONSTRUCTION

DOWELS:NAIDT(lALIGNMENT

1 Boringhedowel olesI Locate ointsor dowels n he board

edgesphoito

bove).oavoid plitting

boards ith he pins, se rooved owelsthatareno more han ne-halfs h ickas he stock. ita drillwitha bit he amediameter s hedowels,henwrap stripofmaskingape round he bi t o markthe dr i l l ingepth, hich hould e l ight-ly more hanone-halfhe ength f hedowels. eep hedrillperpendicularo heboard dge s youboreeachhole righ),withdrawinghebitwhenhe maskingapetouches he stock. Al thoughhe dr i l lpress analso e used o bore he holes,keepingonger oards teady n hemachine 'sablemay rove ifficult .)

Marrywoodworkers sedowels o helpwith the alignment f boards n a pan-el.One of the problems n using histechnique s that the wood ins haveto beprecisely entered n the edgesof the boards o be oined. n thephotoat left, ocation ointshave eenmadefor the dowels-one about 3 inchesfrom each ndof the boards nd onein the middle.A line s then scribedacross hepointswith a cuxing augeset o one-half he hickness f thestock. he ines ntersect t thecenterof the boardedges, uaranteeing er-

fectplacement fthe dowels.

25



CARCASE ONSTRUCTION

r) Pinpointingating owel otesL lnsert dowel enter he same iameter s he dowelsin each f he holes above),hen et he boardslaton heclamps ith he riangle ark acing ou. lignhe ends fthe boards ndbutt he edge f he second oard gainstthat f he irst . he ointed nds f he dowel enters i l lpunch mpressionsn hewood, rovidingtartingointsorthemating owel oles. ore hese oles o he same epthas n step , hen epeat he procedureor he hird oard.

Gluingp he oardsApply lue o the board he same wayas when edge

gluingpage 1).fhen se pencilip o dab small mounof adhesiven he bottom feach owel ole. void preadiglue irectlyn he dowels;hey bsorb oisture uicklyndwil l wel l , akinghem iff icul to i t nto heir oles. nsethe dowelsabove),hen ap hem nto inal osit ionsinga hammer. void oundingn he dowels;hismay auseboardo spl i t . lose p he oint, hen ightenhe clamps(page 2). Removehe excess lue page 3).

ilIllll lttill ililll lllll iltlt llJl[ iltllllltltljl1HO? TI?lnoerling dowele witha deplh 0au0eTo avoidNhe isk of oplittin7boards when nseilinq dow-els ,use hie oimple

ehoV-made epthqauqe. ipa f-inch-longboard o a Nhick- '/'

neee hal ie exactlyone-halt he lenqth f Nhedowele. orea hole haN solightlywiderNhan he t.hick-ness of Nhe owele hrou7h he gauqe ear one end.Then place t around each dowelwhen ou Nap X nNoits hole. he dowelwillbe aN T,he orrecl deobh wheniN s flush with he Lop of Nhe epth qauqe.

26



CARCASEOINERY

f here re manyways f oining ar-J. case anels ogether. he pages hat

followwill examine hree of the mostpopular choices: ovetail, abbet and

plate oinery.As shown n the photo atright, he nterlocking ins and ailsof a through dovetail oint givebothsolidity and distinctive ppearance.Cutting uch oint with the radition-al hand ools s considered rite ofpassage or aspiring woodworkers. trequires kill and practice o perfect.It also eaves oom for creativity, inceit allows ou to choose he width ofpins and tails o giveyour oints an

esthetically leasing ook. The samejoint can be executedn far ess ime,butwith equal precision, sing a router anda ig; that approach s demonstratedin the Drawers hapter page 0-81).You may also want to try the half-

blind dovetail,which s examined npages 2-84.

If you prefer somewhat implerforms of joinery, ry either he rabbet

or the plate oint (page 4-37). Bothare deal or joining plywood pan-els,which are not suited or dovetails.Whichever ype of joinery you select,you must plan ahead or the ater stagesofyour cabinetmaking rojects, uch asinstallingback panels, helving, dgebanding r drawers. ome rawer-hang-ing methods, or example, equire outo rout a groove n the side anels eforethe carcase s assembled.

D()VETAILOINTS

thoulder line

Half-pin

X X X / \ X X X

' l 0utlininghepinsI Markhe outsrdeace f each anel itha bigX, hen et acutt ing auge o he hickness f he stock nd cr ibe l inealongheends f he ourpanelso mark he shoulder f he pinsand a i ls . hepanelshatwi l l orm he op and bottom f hecarcase i l lbe he pinboards . ecure ach ne n urn n a viseand se doveta i lquareo out l inehe pins n he ends f heboard s shown n he sequence bove. tartwithhalf-pins teach dge, aking ure hat he narrow nds f he pins re ntheouts ideace f he board. ext u t l inehe waste ect ionsadjacento he half-pins,henmark he center f he board nd.

Out l ine pinat he enter ark , hen ut l ine he emainingpins above, ight),marking ll hewaste ections ithXs.(You an lso se s l id ing evel augeo out l inehe pins ;set an angle f about :6 orsoftwoodr1:8 or hardwood.)There re o igid uidel inesor he number fpins r orthe spacing etweenhem. utevenly paced ins hat reat east ne-half he size f he waste ections roundhe mmake oran attractivend ol id oint .Use combinat ionsquare o extend l l hedoveta i l arks o hat hey eachthe houlderines n both aces f he boards .



CARCASECONSTRUCTION

r) Cuttinghe pinsZ- Secure he irst pinboard n a viseso hat he outsideace f he panel stoward ou.Use dovetail aw o cutalong he edges f he pins, orkingro mone ide f he panel o he other. omewoodworkersrefero cut all he eft-handedges irst , hen move n o he ight-hand dges. or ach ut, hold he panelsteady ndalign he saw lade ust o hewaste ide f hecuttingine.Use mooth,even trokes, llowinghe saw o cut onthe push lroke right). ontinue awingr igh to he hou lderine ,making ur etha t he b lade s perpend icu la ro heline.Next, se coping aw sfep ) ora chisel step ) to remove he wastebetweenhe pins.Repeathe procedureat he other nd f he board nd t bothends f heother inboard.

QRemovinghewaste ith coping

r-J Stand n he other ide f he panand begin utting way he waste oobetweenhe pins. t he ide f eachsl ide coping aw lade nto he kerfrotate he rame ithout trikinghe enof he board. utoutas much f hewaas ou anwhile eepinghe blade b%o nch bovehe shoulderine.Cut /until ou each he kerf n he edge fadjacent in.Pare way ny emainiwaste itha chisel step ).

2B



CARCASECONSTRUCTION

Removinghewaste ith chiselSet he panel uts ideace pona work urfa ce nd

clamp n a guide lock, l igningtsedge bout %o nch othewaste ide f he houlderine .Using wood hise l o

widerhan he narrow ide f he waste ection, utt he lats ide f he blade gains t he guide lock. oldhe endofthechisel quareo he ace f he panel nd trike t withawooden allet left), coring ine bout s-inch-deep.henturn he chise lowardhe end f he panel bout% inchbelowhe surface f he wood nd have ff a thin ayer fthe waste below). ontinuehaving wayhe waste n hisfashion nt i l ou re bout a l fwayhroughhe hickness fthe panel ,henmove n o he next ect ion. hen ou averemoved l l hewaste rom his ide , urnover he panel ,andworkrom heother ide nt i l he pins re l lexposed.

f, Final aring\, , Withhe panel uts ideace p,a l ignheedgeofa guide lock i th he houlderine n he paneland lamp t n place . utt he la t ide fa chise lagains the block, ndusing our humb o hold heblade er t ica l , entlyapon he handleo pare waythe inal sliver fwaste left).Repeat he processbetweenhe other ins nt i l here s no wastebeyondhe houlderine .

29





CARCASE ONSTRUCTION

Q Cutting he ails and emoving aste(J Use a dovetai l aw o cut he ai lsthe same way you cut the pins step 2) .Some woodworkers nd hat angl ing he

b o a r d , s s h o w n a t h e r h a n h e s a wm a k e s h e c u t t i n g o e a s i e r. n e i t h e rcase, aw smoothly nd evenly, nd stopjust a fraction f an nch before ou eacht h e s h o u l d e r i n e .R e m o v e h e b u l kof the waste withei ther coping aw(step 3) or a chisel step 4), then pareaway he nal bi ts of waste own othe shoulder ine (step 5).

Dry-fittinghe carcase

Beforeluing p he arcase , ssemblet o checkthe i t of a l l he oints . tand ne of he pin boards na w o o d l o c k , h e n a l i g n m a t i n g a i lb o a r d i t h t ;support he other nd of the ail board witha sawhorse.Press he oint ogether y hand as ar as t wil lgo ,then ap he wo ends he rest of the way nto place,whileprotecting he workpiece ith a scrap board. oavoid inding nd damaging he pins , lose he ointevenly long ts whole englh left). oin he other pinand ai l boards he same way, apping nlyon he ai lboard. he oints hould e ight enough o requirel i t t le ent le apping, ut avoid sing xcessiveorce.

l f the oint s clear ly oo ight , mark he spo twhere tbinds, hen disassemblehe panels nd use chisel opare way little more wood.DryJit he carcase gainand make ur ther djustments ,f necessary.f there sanygap between pin and a tail, nsert thin wedge ofi l l i I (page 2) . AI this point , ou wil l need o seet o t h e o t h e r e q u i r e m e n t s f y o u rp r o j e c t , u c h a sinstal l ing backpanel page & and edge anding( p a g e 9 ) , f d e s i r e d , h e n p r e p a r i n g h e s i d e s o rshelves page 1) or drawers. nce hat s done, lueup he carcase step 0).

3 1



CARCASE ONSTRUCTION

' lf\ Gluing p he carcase

I \J ro app lyproper ressure het i g h t e n i n gh e c l a m p s , s e o u r w o opads pec ia l ly o tched ordovetai lo i

M a k e h e p a d s h e s a m e e n g t h s hcarcase ane l s rewide, nd cu t awal i t t le r iangular o tches o ha t he wowil lon lymake ontac t i th he a i l s ano t exert ressure n he p ins .Applyth in bead f g lue n he aces f he pand a i l s ha t wil lbe n con iac t hen hjo in t s reassembled . se a small , t ibr is t led rush o spread he g lueeveleav ing o bare po t s . s semble he ccase nd ns ta l l wo bar c lamps c rosthe aces f each f the pin boards n

turn.Tighten he c lamps l i t t lea t im(left)unlil a littleglue squeezes ut othe oints.Remove he excess lue pa23) , and eep he c lamps n place nthe g lue s d ry.

lllt]lllll lll llrll]ll litlil lr lltll [ llll lr ll1]ljHO? TI?Dealingwith adefeclive dovetailEven eliqhN rrorin cuLNinq oveLailecan esull n a smal lqaV beNween Vi na n d a I a i l . l t h e q a p osmall , i l l t wilh a thin rian-qular hiV f veneer r a wood hav'inq u t t romthe Vane l lock .TomakeLhewood hip ees obvioue, ut itrso hat ito qrainwill unin he same irection e hat of he Vino. se dovet i leaw o eLraighNen ut or deepen he gap, f neceooary.AVVIy liLNlelue n Nhe aVand nserl he chip, hichshould iNenualv.

32



CARCASECONSTRUCTION

llll lltll lll ll1lt ll1ll ll ]ltllllltllIll lll ll lll lt11HO? TI?Checking carcaoe or equareTo Vrevenl clamp Vreooure rompul l inq carcaae ul of oquare ur-in4qlueu?, meazure he diaqonalo

beNween pposiLe ornerl immedi-ately after IiqhNeninqhe clampo.The Lwo esulf,s houldbe heeame. f Nhey re noL, he carcaeeie outof equare. To correcNNheproblem,oosen he lampe, henolide ne aw of each lamp awayfromthe oint aL oppooihe ornersae ehown.Tiqhten he clampe nd check qain or 6quare ,ohifLin7Ihe lampo 6 neceobary nt i lNhe arcaoe o oquare .

CARCASE-SOUARINGLOCKSUnless ouare nstalling backpanel na carcase, t can be diffi-cult o keep he our ides quaredur ing lue p.Ashop-madear-case-squari g block right)placedon each orner i l l help greatdeal. or ach lock, uta piece f3/q-inchlywoodntoan B-inch

square. ita drillpress ran electricdrillwitha 2-inch-diameterole aworcircle utter, hen bore n open-ing n he center f he block. Th eholewil lprevent lue queeze-outfrombondinghe blocko he car-case.) ext, utfit our able awwitha dado ead hat s he samewidth s he hickness f he stock.

Carcaoe-aquartnqblockB " x B "

and cut wo grooves t rightanglesto one nother, ntersectingt hecenter f he block.

To use he ig,apply he glueand assemblehe carcase,hen ita blockover ach corner left),center inghe hole t he pointwhere wopanelsoin.Make urethat he dadoes n he blocksitsnugly roundhe edges f he pan-els. nstall nd ighten he clamps.

J J



CARCASECONSTRUCTION

RABBETOINTS

1 Cuttinehe abbetst -

I Mark cutting ine or he width fthe abbet n he eadi ng dge f ones ide ane l . hen , ns ta l l dado eadsl ight ly iderhan he abbet nd oweri t be lowhe ab le . c rew nauxi l i a rywood ence o he saw's ip ence ndmark he depth f he abbet n t; hedepth hould eone-halfhe hicknessof he stock.With he metal ence learof he dado ead, osit ionheauxi l iaryfence ver he able pening. urn nthe saw. aisehe blades lowlynto he

wood p o he depth ine. urn ff hesaw nd ine p he panel nd uxiliaryfence orcuttinghe abbet. lampfeatherboardo he ence bovehedado ead o hold he panel ecurelyagainsthe able. urn n he saw ndmake he cut above),hen epeat heprocessor he emaining abbetsn heside anels.Caution:lade uardremovedorclarity.)

Quickand easy o cut and assemthe abbet oint is dealfor both owood ndplywood arcases. he ois made p of a board r panel hatintoa rabbet ut on its mating ie

Thewidthof he abbet houldequal o the hickness f thestock.

carcase, he oint is best ut nto thepanels o hat the endgrain of the

and bottom will becovered. lthoustronger han simple utt oints, ajointsfrequently equire crews r na

for reinforcement.

fil llt ll lll it tl ]IrIJll lll lll iltlrllt llt lll i1HO?Tt?lnvisiblenailerTo conceal ailedriven nLoa car-caoe panel, oea b l ind a i l e r.The ommercialdeviceworks ike

a mini-plane,l i t t-in7a lh in woodehavinq nderwhich nail an be driven.The havinqcan Lhen e qlued iqhl back own o hide he nail head.)et up he nailer ollowing he manufactrurer 'sns l ruc-Lions-uou ally or a 1/zz-inch-t ick oh vin , And p aclioeon a 6cra? board efore oin7 he nailer n an aclualworkpiece. he ehavinq ou aiee musl be on4 enou4hto leN ou drive he nailcomforLably. ebriV of Iape willhold he ehaving own while he lue e drying.

34



CARCASECONSTRUCTION

Gluingp he arcase1- Dry-fithe carcase,hen make ny ther ecessarypreparat ions ,uch s ns ta l l ing back anel rprepar ingthe s ides orshelving.hen, pply hin bead f adhesive

in he abbets nd n he contact ingurfacesf he opand bottom anels . se brush o spreadheglue venly,leavingodry pots. ssemblehe arcase nd ns ta l l wobar lamps crosshe op and ot tom anels , ro tect ingtheworkpiecesi thwood ads . ightenheclamps i t t lea t a t ime unt i l lue tarts o squeeze utof he oints.Reinforcehe oints i thscrews bout inch om heedges f he op and bottom anels;oraddrtionaltrengih,dr ive ore crewsn he middle.fyouwish o concealhescrew eads i th wood lugs, ore oles n wo tagesusing n elect r ic r i l l t tedwith wodifferent i ts . irst ,use spade i t wide nougho make oles or he plugs;

then wi tch o a wist i t s l ight ly iderhan he screwshanks ormaking learanceoles . ore heclearanceholes eep nough o each he ide anels ;nglehedr i l lslightlyowardhe nside f he carcaseo ncreasehegripof he screws. hen, rive he screws ntoplace right).

? Installingood lugsr-,1 To ecure he plugs, pply dabofglue o he screw eads,hen nser ta plug nto ach ole /effl, ligninghegrain ith hatof he panels . ap heplugs n place i th wooden a l le t ,then se wood hise l o r im he pro-ject ing tubs lush i th he surface fthe panels . inal ly,emove ny xcessglue page 3).

35



CARCASE ONSTRUCTION

PLATEOINTS

Although t lack the allu'e of luud-ctft dove-tails, he plate or biscuit oirt hns grownin popularity n recertt ears tecause f itsstrength nd sinrylicity.Tlrc oint is ctrt witha plate oiner, showrr rr he photo nt left. Thetoolworks orrrewhntiken rrirtiotttrccircrtIar saw, with n retractable lade hat plungeinto mating workpieces. lue s npplied andan oval-shaped iscuit of corrtpressed eeclris nserted tto rtntching slots rreach ieceThe carcnse s therr ossentbled. irtcehe bladprojectsfront the tool orily while it is ctrttirrgthe plate oirrcr is very safe o use. Guide lineson the base late of the nnchine rnake t u sir'ple nntter to nlign the

slots rr nnting boardsThe slots re cut slightly nrger hnn the bis-ctrits, erntitt ing n small rnargin of errorwhile still ennn'ing a properly aligrecl oirtt.

' l Markinghe ocation f he ointsI _

I ldent i fyhe outs ide ace f each an-el withan X, hen mark ocat ion o in t s orthe s lots long ac h of the our corners .Star twithone of he s ide pane l s uts ideface downon a work ur face nd ho ldthe op pane l t a 90 ' ang le o t . Usep e n c i l t om a r k i n e s h a t o v e r l a ph eface of the op piece nd he end of thes idepane l bou t inches n rom eachcorf l€r ; ake thirdmarkmidway longthe edge .Wider ane l s i l l equire ddi-t i o n a l i s c u r t s ;n g e n e r a l , h e r e h o u l dbe one biscui t very to 6 inches . a rksimilar lot ocat ion o in t s n he o therthree orners f the carcase.

\. i''It..

/'

'\..,.

)loL locaLion ark

36



CARCASE, ONSTRUCTION

r) Cuttinghe slotsL Leauinga ide anel utsideace own n he work urface,set he op piece utsideace p on opof t. Offset he ends fthe wo workpiecesyan amount qual o he hickness f hestock.Make ure hat mat ing lo t ocat ion arks n he wopanels reperfectlyligned. rotectinghe op panel ithwoodpads, lamp he wo workpiecesn place nd e t n ront fthem suooor t oardhe ame hicknesss he stock. his e t -upwil la l low ou ocutall he lots orone orner f hecarcase

without ovinghe panels . o l lowhe manufacturer 'snstruc-tions orset t inghe depth f cuton he pla te oiner ;t usual ly

depends n he size f biscuit eing sed. Resting he platej o i n e r n h e s u p p o r t o a r d , u t t h e m a c h i n e ' s a c eplate gainst he end of the op panel nd al ign he guidel ineon he aceplate i tha s lot ocat ion ark n he stock.Holdinghe oiner i thbo thhands, ut a s lot at each mark(lef i l . fo ut he mating lots n he side anel , ut t he oin-e r ' s a s e l a t e g a i n s t h e o p p a n e l n d h e n a l i g n h ecenter uide ineon he base latewitha slot ocation ark

on he op panel righil.Followhe same procedure o cuts lots t he other lot ocat ion arks .

Q Gluingp he arcaser-J 0nce l l heslots ave een ut , dry-fi the panelsand nsta l l back anel f hat s part fyour es ign, rmake eadyorshelves rdrawers .hen lue p he car-

case: et he side anels utsideace own n a work ur-face, nd queeze bead f glue nto ach lot nd longthesurface f he panels etweenhe slots, nserting is-cuits s you o @fl. Repeator he op and boftom anels,this ime mitt ing he biscuits . opreventhe woodenwafersrom xpandingeforehe panels re ssembled,do hegluing pas quicklysposs ible ,i t t inghe stdep a n e l s n he bo t tom a n e l n d h e n d d i n g h e o p .Installwobar lamps crosshe op andbottom anelsand ighten he clamps xactlys ouwould hen luingup a carcase ith abbet oints@age 5).

3 7



CARCASE ONSTRUCTION

INSTALLINGBACK ANEL

'l Routing rabbetor he panelI Fi t he panelsogether nd et he carcase na work urface ith tsbacksideacing p; nstall bar lamp ith support oard crosshe opand bottom anels, sshown. nsta l l 3/s-inchrabbeting i twi th ball-bearing i lot nyour outer,hen et he depth djustmento cut %o nchdeeper han he hickness f he back anel ouwil lbe nstall ing. tart ingat one orner, est he outer's ase late n he support oard ith he bi tjust lear f heworkpiece.riphe outerirmly ithboth ands nd urn ton , u id inghe b i t n to he pane l . nce he p i lo t u t t s ga ins the tock ,pul l he outer lowlyowardhe adjacent orner, eepinghe base la teflat.When ou each he corner,urn he outer ff.Repositionhe supportboard nd ut abbets longheedges f he hree emaininganelsn hesame manner above).

r) Squaringhe orners1 tlse pencil nd straightedgeo masquare ornersn he ounded nds f hrabbets. elect wood hiselhat s widenough o inish ff hecorners rth woperpendicularuts. t each orner, tanthe ipof he chisel n he mark hat unacrosshegrain,making ure hat he bevfaces he nside f hecarcase. se wooen malleto strikehechisel above),uttito he depth f he abbet. l ignhe hiswith heother ark nd trikehe handlagain. Makinghe utwith he grain rsmay ause he panel o spl i t . )

Q Installinghe panelr-,f Cuta piece fplywoodo it snuglynto he ab-bets n he back f he arcase. lue p he carcaseand, t he ame ime, pply hinglue ead longthe abbets or he back anel nd n he contactingsurfaces f he plywood. preadhe glue venly,etthe panel n posit ion,hen se mall a i lso secureit at 4-inch ntervals/effJ.

3B



EDGEBANDING

D dg. banding s he usualwayof con-Ij cealing he visible dges fplyruoodpanels nd shelves;t creates he llusionthat he carcase s made exclusively f

solidwood. You can choose ne of twooptions: Commercial dge banding,shown on page 0, s available n a widevarietyof wood ypes, olors and hick-

SHOP.MADEDGEANDING

1 Applyinghe bandingI Use he able aw o cut hinstripsof edge andingrom board; esure ouse oush tick o eed he stock nto heblade. ake he strips l ight lyongerhanthe panel nd t eas t s wide s he pan-el s h ick.Grip he panel teach nd na handscrew,hen lamp he handscrewsto a work urface o hat he ront dge ftheworkpieceaces p . Then pply htnglue ead o he edge f he panel ndusea small, tiff-bristledrush o spread headhesivevenly. enterhe banding longthe panel ' s dge;o hold t la twhi leheglue r ies , ape t very rmly t 2- inchintervals . se s many trips f ape snecessaryo eliminate ny aps etweenthe banding nd he edge f he panel .

nesses. nstallingt is simply matter fcuttingoffthe engths ou need rom aroll, setting he banding n place andheating t with a household ron to melt

the adhesive hat bonds t to the surfaceofthe wood.Although somewhat more painstak-

ing to apply, hop-made dge anding

offers everal dvantages ver he store-bought solution. oucan make t fromanv available ood species nd cut itto whatever hickness you choose;

7s-inch-thick anding s ypical. Th eshop-made ariety s also ess xpen-sive-a consideration f you plan touse a ot ofbanding.

r) Trimmingxcess anding

Z Oncethelue

as r ied ,rimany dge andinghat

projects eyondhe panel dges. ita router ith a flush-cuttrng i t , hen est hemachine 'sase la te n he paneledge i th he bi t ust lear f he excess anding. oldingthe outer irmly i thboth ands , urnon he motor ndguide he bi t n to he excess anding. nce he bit 's i lo tbutts gainst he panel, uide he outer lowly gainst hedirect ionf bit otationo he opposi te ndof he work-piece . ake ure hat he base la te nd he pilot emainf lush i th he panel . ight lyand heedges nd nds fthe bandingo remove ny emainingnevenness .

39



CARCASECONSTRUCTION

SETF.ADHESIVEANDING

1 Applyingheedge andingI Set householdron nHigh withoutsteam) ndallowt to heat o.Meanwhile.apply lampso hold he panel pright,and uta strip f banding l ight lyongerthan he edge o be covered. et he band-ingadhesive-sideown longhe paneledge . o ld ing he band ingn place i thone hand, un he ron lowly longhepanel dge, ressinghe rim lat. The eatof he ronwil lmelt heglue nd oin hebandingo he panel. eep he ronmov-ing; esting t on one pot or more ha na few econds ill eave corch arks.

r) Flatteningut he rimL Applyingevenressure,un asmall and oller ack nd orth longthe ength f he edge andingo

smootht outandbond t irmlyo hepanel dge. have ffanyexcessbanding itha aminate dge rim-mer or a router page 39).

llltlllllJit]IJlllll]lll lllll]lt lllIJllJllllllll1HO? TI?5 pringb ard f o alampingedge bandingFor hick edge bandinq, Nma ybe neceeoary o clamp Lhe band-inryo a panel dqewhileheglue riee.For typical panel,you miqhL eed Nhree r fourbar clampo; einqle lampwilluffice,howevenifou uee ohop-made prinqboard.To ak ethe device, ut a genble urve-r/+-inch-deep L iIs cone ed7e of a 2-inch-wi de oard he eami lenaNh nd Nhicknessae he panel. enter he anel n a bar clamp nd seNVhe on-cave d4e fthe epringboard qainof,lhe dgebandinq.Ueewood pad o prolecl the Vanel, i

Ihe epringboard gaineL he edge andinq. eprotecl the Vanel, i4hten he clamp unLilNh eoodpad o prolecl the Vanel, i4hten he

epringboard latlens aqainel he bandinq.

40



SHELVING

HIDDENDJUSTABLEHELF UPPORTS

I ddingshelves o a carcase s one wayf\ to turn a simple wood box nto auseful iece f furniture.The simplestmethod or installing helves s o bore

two parallel ows of holes n the sidepanels f the carcase nd nsert om-mercially vailable lasticor metal shelfsupports. he wo alternatives hown nthischapter equire ittle more prepa-ration, but they have a payoff n thatthere re no visible helf upports o marthe appearance f the inished iece. ikecommercial helf ardware, idden up-ports below ndpage 2)are adjustable;the difference s that hey ely on nar-rowwood strips ecessedn rabbets ut

into the underside f the shelves, ndthis makes hem all but invisible.

For ixed shelves page 3),youhaveto rout dadoes n carcase ides. heshelves re hen glued permanently nolacewhen he carcase s assembled. Many woodworkers se ommercial helf-drilling igs o help with the

job of boring arallel owsof holes. lamped o the edge f the panel,the igensures hat he corresponding owsareperfectly ligned. he igin thephotoallows ou o bore oles t l-inch ntervals nydistanceromthe edges f thepanel. For most rojects inches n rom the edges s ypical.

1 Makingnd nstallingI ttre tretf upportsBore oles or he shelf upports singcommercialig.Afterhecarcases assem-bled,make wo uppor ts er hel fForeach f he m, ut a h in strip f woodabout inch onger han he gap etweenthe ows f holes; ake he stripwideenougho hold dowel t each nd. omark osi t ionsor he dowels ,nsertdowel enter nto ach f wo paral le lholes,hen press he wood trip gainstthe ooints . se he ndenta t ionsor hedowel enters sstarting ointsorboringthe h o l e s . a k e h e h o l e sn h e h e l f -support ieceshe same epth s heho lesn h e i d e a n e l s. lue owelsinto he shelf upports, ndwhen headhesive as r ied ,ns ta l lhem n hes ide anels t he heighthat ouwantthe shelf o rest.

4 1



CARCASE ONSTRUCTION

r) Making nd reparinghe helvingZ- Use olid umber, lywoodredge-gluedboards page 0)to make he shelving. uteachshelf o he same idth s he arcase anelsand o a length qual o he distance etweenthe ide anels. dd dge andingo he is ibleedge f he shelf page 9), f desired. ocon-ceal he supports, out topped abbets n heshelf Start y posit ioninghe shelf n he up-ports nd utl iningheir ocations n he under-side f he shelf . sing wood ad o preventanymarring,lamp he shelf o a work urface.Fi ta router i th a rabbeting it , hen et hedepth f cut o he width f he shelf upports.Grippinghe ool irmly ith both ands nd est-ing ts base late n he shelf, out ach abbet(abovd,making smany asses snecessaryocut o he marked utline. quare he ends fthe rabbets sing chisel page B).

Q Installinghe helving\Jt With he helf upports t hedesired eight n he ideels, est-fit he shelf n he carcase above). se chisel o adjthe ength, idth r depth f he stopped abbets, f necessarensure perfect t hat ompletelyideshe shelf upports.

/1 )



CARCASECONSTRUCTION

FIXEDHETVING

r) Making nd dry-fittinghe shelvingI tlsesolid umber, lywoodredge-gluedoards(page 0)to make he shelving. uteach helf othe same idth s he carcase anels nd o alength qual o he distance etweenheside an-elsplus he depth f he dadoes. dd dge andingto he visible dge f he shelf@age 9), f desired.Tocheck he i t of he shelving,oin he opand

bottom anels f he carcase ithone ide anel,then it the shelvingnto he dado ighD.FiItheother ide anel n op. Adjusthe ength r widthof he shelving,f necessary,o ensure perfectit.

1 Preparinghe arcase ide anelsI Set he side anels ne n oo of he other na work ur-face , dges nd nds l igned, ndmark ut t ing ines or hedadoes n he eading dges f both anels . ake hewidthof he dadoes qualo he hickness f he shelf ;he depthshould eone-halfhe hickness f he ide anels .ns ta l ldado ead n a able aw nd l ign he cutt ingines n oneside anel ith t. Crank he blades o he proper eightorthe depth f cut, hen ositionhe ip ence lush gainst hepanel. uta est dado n a scrap oard nd adjust he widthof cut f necessary. lamp featherboardo he ence bovethe dado ead oradded tabil i ty.omake he cut n eachpanel, urnon he saw nd eed he panel nto he dado eadusing he miter auge ndboth ands /eft).Caution:ladeguard emovedorclari$.)

Q Gluingp he arcase

r-J Apply hinglue ead nto he dadoesn he srde anelsand n he contact ingurfaces f he helving hi le luingup he ar case. preadheglue venlynd hen ssemblethe box s when ry-fittingstep ).Clamp he corners f hecarcase ordovetailoints@age 2) or or abbet r platejoints paEe 5).For he shelving,nstall bar lamp crosseach dge f he shelf protectinghe side anels ithwoodpads; lace %-inch- thickood hipunder ach ad ofocus ome f he clamping ressure idway etweenheedges f he helving.ighten ach lamp itt le ta imeunt i l h inglue ead queezes utofeach ado.

43





Thisclamping etup ocuses ressure n thecorner oints to ock ogether he componentsof a rame-and-panel ssembly. hile gluebonds he corners, o adhesive s applied nthegrooves hat hold he panel, allowing t

to move s he woodexDands nd contracts.

Theopeningn the rame s illedby a "floating"panel, hich its ngrooves ut n the ailsand stiles.Thepanel s said o floatbecauseit is not glued n place. ather, t

merely its n its grooves ith roomfor movement. f the panelwereglued n place,he assembly ighteventuallyplit.

Panels re set nto their sur-rounding rames ithout glue ominimize arping. ut n additionto their structuralunction, anelsalso erve n estheticole.They reoften raised"-that is, hey havebevels utaround heiredges. hisnot only makes hem easier o fit

into grooves, ut also iveshemdecorativenterest.

Mounted upside-down n a table, routerfltted with a coping itcutsa tongue t the end of a rail.Anotherbit will cut a matchinggroove nto the stiles,makinga solid and attractive ope-and-stickjoint, one of the hallmarlcs f rame-and-panel onstruction.

FRA4E-AdD-PN\TELCONSTRI.ICTION

rame-and-panel oinery wasinvented about 500 years ago)

probably y a frustratedmedievalcraftsman eterrninedo finda bet-terway o build cabinetshansimply

fixingboards ogether. majordrawback f wood as a buildingmaterials ts endencyowarpandsplit.Frame-and-panel ffers solu-tion o these roblems.

Ever-changing oisture evelsin the aircause ood o move, spe-ciallyacross he grain.As relativehumidity ises, wood swells; sthe moisture ontent alls,woodshrinks. hecentral eatingoundin mostmodern omes ompounds

the problem. n a heated bme nwinier, he elative umidity androp as ow as 0 percent; n summer t can soar o 85 percent.The difference etween he wo evels an significantly hangethe cross-grain imensions f a pieceof wood.

Frame-and-panel onstruction s designed o accommodatethe movement f swelling nd shrinking wood, esulting n fur-niture hat s both strong and stable. n the ypical piece hownon the two pages hat follow, ndividual rame-and-panelassemblies re oined together o form a four-sided abinet.Each ssembly omprises wo verticalmembers-stiles-andtwo or more horizontal ails, all ocked ogether y any one of

a variety of oints. These an nclude dowel,plate,miter-and-spline and ap oints. This chapter will showyou how o use hehaunched mortise-and-tenon page 8)and he decorativecope-and-stick oint (page 1 .

Wth one rame-and-panel ssembled,ouneed nlyrepeatthe process ndvary t slightlyo build a cabinet page 9).Usually,lvoassembliesre oined ogether ith side ails ndpanels, ith he ront assemblyeftopen or a door.

Asyouwill see n the pages hat ollow, rame-and-panelconstructions aversatileurniture-buildingystem. ou anaddabottompanel o a cabinet page 0),hena op (page )and either ixed r adjustable helvingpage 1).lnstallingmolding page 9) ides heconnection etweenhe rame ndthe op; t also dds decorative lourish.

Althoughhismethod f construction s more difficult omaster han building simple arcase, he esult s a sturdy,functional nd attractive iece f furniture,whichmakes ll hetimeand effortworthwhile.

45



ANATOMYOF A FRAME-AND-PANEL SSEMBL

espiteheirdifferences,he rame-and-panel ssemblieshatmake p

a ypical abinet ave lementsn com-mon:Namely, ramesmade rom rails

andstiles, nd panels hat it into groovesin the rame. ottoms nd ops re su-allyadded, long with shelvingn manycases. hese omponents re ypicallymade f edge-glued oards f he samestock sed or he rame.

Individual abinets ill feature ari-ations. n some nstances,he sides illshare tiles with the front and backassemblies ith rails itting nto both heedges nd he aces fthe stiles. o pro-videaccesso the nside f the cabinet,the front frequently as a frame butno panel.Sometimes, median ail sused o divide he opening nto twodiscrete ections.

The womost ommonointsn rame-and-panel abinets te he haunchedmortise-and-tenon nd he cope-and-stick The haunched ortise-and-tenonoffersgreater luing surface han hestandard ortise-and- enon,making ta very strong oint. The haunch lsofills n the end of the groove ut ntothe stiles, liminating he need orstopped rooves. he cope-and-stickjoint provides omparable trengthand adds ts own decorative ouch.The outer bit that cuts he groovesfor the panel alsocarves decorativemolding n the nside dges f he rame.Whatever he oint, cabinetmakers su-allybuild frames rom %-inch tockthat s at least2 incheswide; argerstockmayalso e used o suit he dimen-sions fa particular roject.

RailFrovidea horizontalaupport at top andbottom of cabinet

StileVerticalcomponentof frame

)olid wood piecethat fit6 into4roove-typically1/z-inch-deep- inframe; can be flatwith edqea rabbet-ed or beveled onfour aidee o "raiae"

center of the panel

46



FRAME-AND- ANELCONSTRUCTION

#r'

ToPUouallyoverhanqa outaide edqea offrame; attached with wood buttona,ae ahown, or with metal faetanera,led4er etripe or pocket holea. Edqecommonly haa routed decoration

Wood buttonUsed o faaten top to frame. One end fitsinto 1roove cut into frame, permittinq ali4htmovement; other end acrewed o top

thelf eupportCan be pooit.ioned n dadoeaat any heiqht inaide cabinatto provide adjuatable ehelving

MoldingConceala oint between opand frame; can be purchaaedor made n the ohop

Thisframe-and-panel abinet s heldtogether y haunched mortise-and-tenon oints. The ront has ailsandstiles, ut no panel. nstead, medianrail serves sa dividingline benveenthe openingsor a door and a drawer.

ShelfMay havedecorativedetail rout-ed alonqfront edqe

I

EottomAttached to frame by ledqeratripa or 1lued nto 7roovecut in inaide edaee of frame

Led4er etripUaed o faaten bottom ortop panel o frame; oneedqe acrewed o frame; oth-er ed1e screwed o panel

47



MAKINGTHEFRAME

f his section f the bookexaminesI the raming echniquesorbuilding

a ypical rame-and-panel ase. emem-ber, owever, ouneed careful esign

for the whole iece f furniture eforeyou make he irst cut on a projectofyourown.

Whether ou will beusing he stan-dard mortise-and-tenon oint, thehaunched ersion fthat joint (right,top), r the cope-and stickoint (right,bottom), alculatehe number frailsandstiles ouwillbeneeding oyoucancut hem all o length ndwidthat hesame ime.Thispermits ou o use hesame ool setup or all he cutting.

For he haunched ortise-and-tenonand he cope-and-stick,oumust uta

Ha unched mo tiae- a nd tenon ioint

Cope-and-etick oint

groove or the floating panel alonginside edges f the rails and stiles.groove s typically Vq nch wideVz nch deep, and the panel s cu

dimensions hat allow + nch of its eto sit n the groove. f you opt for mtise-and-tenonoints, ou alsoneecut a haunched---or otched-tenonthe ends of each ail to accommodatepanel. For rames with no panels, uthe ront ofthe case hownon pagyou have o cut standard mortise-atenons. o produce his oint, followsame procedures sed n makingframe of a rame-and-paneldoor104).Whatever ype of tenon you de

to make, cutit3/+ nch ong and he sathickness s he groove n the stiles

HAUNCHEDORTISE.AND.TENON(lINTS

1 Cuttinghe enons n he ailsI Install dado ead lightly ider han he ength f he enonson a able aw, hen attach n auxiliaryence nd aise he bladesto cut a notch n it . Set he width f cut eoual o h e enonlength. o cut he enon heeks, utt he stock gainst hefence nd he miter auge, hen eed t face-downverhe blades.Turn he ail over nd epeat he cut on he other ide. estthe enon n a scrap iece fwood utwitha dado he samesize s he groovesn he st i les ; d jus t he height f he dadohead nd epeat he cuts, f necessary. ext, ut he enon

cheeks t he other nd of he ail (above,eff).Positionhefence o eave haunch qual n width o he depth f he grofor he panel; et he height f he dado ead o cut aboVz nch nto he enon. With he stock n ts edge, se hefence nd he miter auge o guide t over he blades. epto cut he haunch n he other ide of he enon above,igFor he ails f an assembly ithno panel, utstandardeno(page 04),makinghe shoulders qual o he width f hnotch ou ut nto he haunchedenons.

48



FRAME-AND PANELCONSTRUCTI N

-) Outlininehe mortises<.

r- ,1 Clamp he s t i les ogether ace o face, nds l igned. omark he ength f the mort ises , se a rai l witha s tandardtenon. Hold he cheek f the enon lushagainst he edge fa s t i le o hat he edge f the rai l s al igned i th he end ofthe st i le . ut l ine he width of the enon above, ef t ) .Thenuse a try square o extend he marks dotted ines n the llus-t ra t ion) cross l l he st i les .Repeat t the other nd and orany marks or median ai ls . o mark he widthof he mort ises ,r e m o v e h e c l a m p s n d h o l d h e e d g e f h e e n o n l u s h

against he edge f the stile above ight, op); epeat or heo t h e r t i l e s . x t e n d h e m a r k s l o n g h e e d g e f t h e s t i l ef tot ted ined. o out l in e he mort ises n he faces of thest i les , i rs t mark he ength y extendinghe ines cross heedges f he st i les o the aces . or he width, hold he edgeof the enon lush against he marked ace of the s t i le andout l ine he cheeks f the tenon on the s t i le (above ight ,bot tom).Extend he l ines along he tace (dot ted ines) .Repeat or he other t i es .

\ 0 f f i-

I U f f i

r) Planninghemortisesn he tilesL fus t ,evaluatehe appearancef he boardsor hes t i les nd arrangehem n a work urface i th hei r es ts ides acing own. or our-s ided abinei , uch s he

one hown npage 9,set he t i les n hei r e la t ive osi -tions-one t each orner-and umber hem n sequence,beginningith he ront ef t t i le . h iswi l lhelp ou ear-range he st i les hould hey etoutofsequence. ext,mark heapproximateocat ionsf he mortises, utt ingXson he nside dges nd he ns ide aces t he opsand ottoms f he t i les lef i l , or t i les i th medianrai l ,mark n addi t ionala t he appropr ia teocat ionntheedse f hestock.

49



FRAM E-AND PANEL CONSTRUCTION

,{ Routinghe mortises-t Secure stile n a vise. nstall commercial dge urde na plunge outer,hen crew nto he guide wood xtensionswide s he edge f he stile. it he outer ith a straight itthe same iameter s he width f he mortise ouwillbe cut-ting, hen et he cutting epth. ent er he bitover he marksfor he mortise nd djust he edge uide o butt he extensionagainsthe sti le. r ippinghe outer rmly ithboth ands,

turn t on and plungehe bit nto he stock above,eft). lfyoare using conventionalouter, arefullyivothe ool's aseplate n he stock o ower he bit.)Guide he bit rom ne nof he mortiseo he other. ake s many asses s necessto cut he mortiseo he equired epth. hen, quarehe enof he mortise sing chisel. ut with he beveled dge f hchisel acing nto he mortise above,ighil.

f, Cuttinghegroovesr,f On he a i ls nd t i les , ark ocations or he grooveshatwillhold hepanel. hen etupyour able aw witan auxi l iaryence nd a dado eadthe ame idth s he groove. laceheedge f a railor a stile n he able witthe dado ead ligned o run ight lo

itsmiddle, nd adjust he ence o butagainsthe stock. se eatherboardsohold he workpiece gainsthe encewhi lemakinghe cu t .To u t g roovon he aces f hestiles, eep he encin he same osition:se eatherboarbo th bove nd o he s ides f hestock left), ndcomplete ach asswitha oush t ick.

50



FRAME-AND PANEL CONSTRUCTION

C()PE-AND.STICK()INTS

1 Makinghe ope uts n he ailsI Insert coping it-also nown sa ra i l u t ter-wi th bal l -bear ingi lo tina router, ndmount he machinen arouterable. ou illbe cuttingonguesntheends f he ailso it nto roovesn hesti les. utt he edge f he ai lagains tthe bitandadjust he outer's epth ettingso hat he op of he uppermost utteris slightly bove he stock. osition hefence aral le lo he miter auge lotand n ine with he edge f he bi tp i lo t .Make he cutswitha miter auge ttedwith nextensionndwith he end f hestock utted p againsthe ence /eftl.

r) Adjustinghe height f he sticking itL lnstall sticking it---or tile utter-

wi th bal l -bear ingilot . h is e tup i l l ,in a single rocedure,hape he edgesof he strles ith decorativerofilendcut groovesor he ails nd he panels.To et he cutting eight, utt he end ofone f he completedai ls gains thebit , hen djus the spindle et t ing nthe outer o hat oneof he eeth n hebit s evel i th he ongue n he ai l(right). lign he ence with he edgeof he bitp i lo t .

0

5 1



FRAME-AND-PANEL CONSTRUCTION

Q Cuttinghe stilesr-,1Tosecure he workpiece,lampfeatherboardo he outer able gainstthe outside dge f he stile; or extrasupport, ecure second eatherboard

to he ence bovehe bit.When eed-ing he workpiecento he bit (above),use push tick o complete he pass.

Il[lltlll ll flfllll llllll l|Illlll tlllll jlllll ll ll1HO? TI?A ohop-built miter gaugelfyou do nolhave a 65 _miler qauqe r ifyour rouLer ableio mieeing sloI ,you can u?e aohop-madeiqLoquide etock accu- ,aralely acroeo hetable.WiNht,herouler Lable'e ence

aliqnedwiLhNhe dgeof the bit pilot,cuLaboard haI will over-hang heedqe f Nhe ableby an inch or Lwowhen t iebu|Ied aaainst he fence. crew aohort eu??ort piece o Nhie oard, ounNersinkinqlhe crew6.Then, crew Lhirdboard o the undereide f he oupporL iece.Thielael addibionwill erve e a guide, unning lonq he edqe of Nhe able.Oefore einq he iq, cuN nolch nto it by runninq t paeL NhebiL.

52



MAKINGTHEPANEL

p anels o fit nside our i'antes an eI made f e i ther ly 'wood r edge-gluedboards page 0).To ensure hat apanelwill it snugly n the grooves n the

rails nd stiles, ut stillhave ittle oomto moveas he wood expands nd con-tracts, t is made ubstintiallyhinneron the edges han t is n the middle.Theshape fsuch a so-called aised anel sachieved ot by adding material t thecenter ut by cutting away hicknessat he edges.

There are several aysof making araised anel, epending n the visualeffect ou wish o achieve. commonmethod, xamined n this section f the

book, nvolves eveling he edges fthepanelwith able aw page 4)or outer(page 56).Raised anel cutters or the

router are availabe n several esigns,including ove nd ogee, nd n variousdiameters. ake ure our outer as tleast horsepower o make uch cut.

Before aising panel, ut t to size. sshown below, his demands recision,since here s ittle room or play n thefitbetween he panel nd he rame.

Akhough he design s different, eveling panel's dges ith

a router top) or a table aw below) achieves he sanre fict:Thecenter f thepanel appears aised, hile ts edges resfficientlynarrow o it intoa groove n the rame.

CUTTINGHEPANEL () FITCuttingpanel osizeTest-ft he ai ls nd t i les f he rame,thenmeasureheopening etweenhem.For rame ssembled ith ope-and-stickjoints, easureheopeningrom he back,since he moldingut nto he ront f heframe akes recisealcula t ioniffcul t .AddVz nch o each f he dimensionsfor he openingo allow or he /qinch fstock longhe edges f he panel hatfi ts nto hegroovesn he ai ls nd t i les(inset).The ottedines n he llustrationrepresenthe actual dges f he panel ;the sol id ines epresenthe rame pen-ing . ) u t he p a n e l n h e a b l e a w,r ippingirs t , hen rosscut t ing. or hecrosscut,crew board o he miter augeas an extension,hen oldhepanel i rmlyagainstheextensionndpush hem ogether,feedins he stock nto he blade left).

53



FRAME-AND PANELCONSTRUCTION

MAKINGRAISED ANET ITHA TABTE AW

r) Cutting ith he grainL Setthe panel n edge nd eedi t into he b lade , eep ing he backf lush aga ins t he ence . u rn hep a n e l v e r o c u t h e r e m a i n i n gedge right).Cutting nto he endgra inof the pane l i rs t -bevel ingt h e o p a n d b o t t o m e f o r e h esides-hel ps red ce earout.

1 Cuttinghe end rainI To et he blade ngle, egin ym

ing cuttingine:Draw 7a-inchquat he bottom orner,henmark l infrom he ront ace f he panel hrouthe nside orner f he quareo a poon he bottom dget/anch rom he baface inset) . est he panel gainstauxiliaryood ence ndadjust he anof he blade ntil t aligns ith he marl ine . d jus t he b lade e igh t n t i l ntooth ustprotrudes eyondhe ront acof he panel,hen lamp gurde locthe panel o ide longhe opof he en

Feed he panel nto he blade, eepinf ush ga ins the ence i th our ighand hile ushingt orward long the guide lock ith our efthand leTest-fi the cut end n a groove.f lesthan /qinchof he panel ntershe gromove he ence ittle losero he blaand make nother ass. epeathe cutthe other nd f he panel.

Auxiliary ence

54




Anqledfence12" 3O"

Auxiliaryfence9" x 30"

9upporL

AJIG (lR UTTINGAISEDANETSTo aise oanel n he able aw with-outadjus t inghe angle f he blade,use he shop-bui l tigshown t eft .Refer o the llustrationor suggesteddimensions .

Screwhe ip along he bottom dgeof he angled ence, aking ure oposi t ionhe screws here heywil lnot nterfere ith he blade. rop heangledence gainst he auxiliaryenceat he same ngle s he cutt ing inemarked n he panel page 4I (Usesliding evelo ransferhe angle.) uttriangular-shapedupportso it precise-ly n he space etween he wo ences,then ix hem n place ithscrews.

To use he ig,positiont on he sawtablewith he ointbetweenhe ip andthe angledence irectly verhe blade;ensure hat he screws rewellclear fthe able pening. lidehe ip ence obuttagainst he ig'sauxiliaryence, ndscrew he wo ogether. urn n he sawand rank he blade lowly p o cut akerf hrough he ip. Next, eat he pan-el n he igand adjust he height f heblade ntil a single ooth s protrudingbeyondhe rontof he panel.Makea test cut n a scrap oard he samethickness s he panel, eeding t intothe blade nd hen esting ts it in agroove. djust he position f he enceor blade, f necessary. hen ut he actu-al panel, evelinghe sides ith he endgrain isl (lefil.

55




MAKINGRAISEDANET ITH ROUTER

r) Raisinghe panelL Lowe,he guard ver he bit an dturnon he outer. ominimizeearout,cut nto he end rain f he panel i rs t ,bevelinghe op and bottom efore hes ides . h i l e unn inghe tock as t hebit,keep t flush gainsthe ence ithyour efthand ndpush t forward ithyourrighl right). heoutside ace f he pan-el must edown n he able. urn ffthe outer,hen est-fi the cut end na groove.f the panel its ess han /qinch eep nto he groove,ncreasehecu t t ing ep th y7e nch nd makeanother ass.

1 Setting p he outerI Fi ta router i th panel-raisingi

then mount he ool n a routerable. ensure hat he cutting idth s unifoposit ionhe ence aral le lo he mitgauge lot nd n inewith he edgethe bit pi lo t .With he outer urnedplace scrap oard longhe ence nacrosshe bit o check he posit ionthe ence. he it pilot houldurnas hboard ouches I (left); djust he enceposition,f necessary. et he out era Va-inch eoth f cut.



PUTTING THE PANEL N THE FRAME

f) efore luingup the ails, tiles ndI) panel, ake he ime o dry-fit heparts. fthe pieces o not fit perfectly,make inal adjustments, snecessary.slight shavingwith a wood chiselwillusually o the rick.

Since he ndividual rame-and-panelassembly s only one componeni f apiece f furniture, ome urther planningis required at this stage. ou need odecidewhich methods ou will use oinstall a bottom panel page 60) and arop (page 4). Some of the methods ofinstalling hose omponents equire ou

ASSEMBLINGHE RAME-AND.PANEL

to bore oocket oles n the ails or routgrooves n the rails and stiles. n eithercase, he stock will have o be preparedprior to gluingup.

A belt ander rovides quick ndefficient tart n smoothing he sur-faces fa ftame-and-panel. ere, heglued-up ieces clamped o a worksurface or sanding he aces f thestiles nd ails.The aneland heinside dges f the aik and stilesshould e sanded rior toglueup.

'l Test ssemblinghepiecesI Join ra i l nd s t i le . hen eat he panel e tweenhem. e t he ti le na work ur-face, nd add he second ailand stile abovd. ark ach f he oints sing penciltohelp ou n he inal ssembly, hen ou pplyheglue . f any f he oints s oo ight ,mark he bindingpots, i sassemblehe pieces nd se wood hiselo pare way omewood t he l l - f i t t ingoint . ssemblehe rame gain . nce ou re attsfied i th he i t ,d isassemblehe rame nd and ny urfaceshatwi l lbe difficulto reach nce heassemblyas een lued p.

5 7



FRAME-AND-PANEL ONSTRUCTION

r) Applyinghe glueI VtaV,eour lamping locks ,utt ingthem s ong s he ails rewide nd swide s he st i les re hick. ay ut allofthe componentsn heir elative osit ionswith heir utside urfacesacing own.Formor t i se -and- tenonoin t s , queezeglue nto he mortises nd n he enoncheeks nd houlders;orcope-and-sticklo rn t s , pp ly lue o a l l the on tac t ingsurfaces.neither ase, se ust noughadhesiveo cover he surfacesompletelywhen t is spread utevenly right). onot nsert lue n he panel rooves;hepanel ust e ree o move i thinhesejoints . fter pplyingheglue, ssemblethe ame-and-panel.

Q Tighteninghe lampsr-,1 Lay wo bar lamps n hework urface ndplace hglued-up ssemblyace own n hem, ligninghe ailwrth he bars. o eep he clamps rom al l ing ver, rothem p n notched ood locks . lace lamping locbetweenhe stiles nd he aws f heclamps o avoidmringhe tock nd o distributehe pressurevenlylonghloint. ighten ach lamp n urn ust enough o closethe oints left), hen se rysquare o make ure hat hcorners f he rame re t 90' angles. ontinueightenthe lamps ntil hinbead f glue queezes utof hejoints, heckingorsquare syou o. 0nce he glue adried, emove he clamps. rotectinghe surface i tha wood ad, lamp he assemblyo a work urface. sepaint crapero remove ny r ied lue hat emains n hwood, ullinghe scraper long ach oinI inset).

Notchedwood block

5B



ASSEMBLING FRAME,-AND-PANE,LASE,

ith a ewvariations, ou can epeatthe procedures hown n pages 7

and 5B o join individual rame-and-panel ssemblies nto a piece f furniture.A single rame and panel make up thebackof a small abinet. he ront s puttogethern roughly he same ayusingmortise-and-tenonoints.On this side,however, here s no panel n the rame,but a median ail runnine between he

stiles. n this situation, he ailsand stilescan be oined with standard ortise-and-tenons page 04), ather han hehaunched arietyused or the other

three ides.The side assemblies re dentical o

the back,except or one eature: nsteadof having tiles f their own, he sidesfit into the stiles f the ront and backassemblies.fyou are usingmortise-and-

tenon oints,as n the piece f furnitureshown elow and on the ollowing ages,the enons f the side ails it into mor-tises ut nto the nside aces f the stiles;

iorcope-and-stickoints, ongues ut nthe ails it in grooves outed n the stiles.In both cases,he panels it nto groovesrouted long he nside aces fthe iontand back tiles nd he edees fthe railsbetween hem.

GLUINGPACABINETPuttinghe ase ogetherTest-fi thecase s ouwould hen ry assembl ingsingle

frame-and-panelidepage

7), hen and he nside urfacesof al l he pieces . pply lue o he oints-wtth he excep-tionof he grooveshathold he panels-and ake our inalassembly: e t he back f hecabinetace own nd i t hefour ide a i ls nto ts st i les. ns ta l l thewo ide anelsn hegrooven he back t i les nd he nside dges f he ide ai ls ,Final ly,uton he ront, lac inghe mort isesn he t i les verthe haunchedenons n he ide ai ls . et he ase pr ight ndins ta l lour ar lampsunningrom ront o back ver he ai ls ,protectinghesurfaces f hestiles ithwood ads. ightenheclamps uenlyright) ntil hinglue ead queezes utof hejo in t s . se measur inga p e o check he the rhe case s

square, easur inghe dis tance etween pposi teorners ;

the womeasurementshould eequal . f not, nstall notherbar lamp crosshe onger f he wo iagonals ,e t t ingheclamp aws n hose lready n place . ightenhe lamp i t-t le at a ime,measur ings ou o below)nt i l he wo diago-nals re qual . nce heglue as r ied , emovehe lamps nduse paint crapero remove ny ried dhesive.



INSTALLINGA BOTTOM PANEL

''l"t here re everal ays o nstall bot-I tom on a i'ame-and-panel ase. ne

method hat s popular mong trbinet-makers alls or grooves long he ns ide

faces f the bottom ailsand he stilesprior o gluing p he ndividualfr arre-and-panel ssemblies.hegrooves an emadewith a dado ead n he able aw,and hey should all about 1 nch rom

the op edge f the bottom ails. heyshould eabout z nch wideand halfasdeep s he hickness fthe stock; topthegrooven the stiles t he pointwherethe side ails butt up against hem. Toinstall he panel, arrow ts edges lightlywith a plane, llowinghe piece o fi tsnugly n the grooves, ut not corrpletelyrestrictingtsmovenrent.

Another ypeof installation, hbelow, elies n edger trips,whicscrewed o the bottom ails. Withapproach, he bottom can be nstafter lue p. Using ithermethodbottom s made rom the same tused or the est of the case. akewidthof he panel lightly arroweitsopening o allow or woodexpan

ATTACHINGHEPANEL

Installingedger tripsSaw our 1- inch-squareedger tr ios o f t a long he ai ls t hebot tom f he cab ine t , u t t ing hem lrght ly hor t o make heme a s i e r o i n s t a l l . o r e w os e t s f h o l e s n e a c h t r i p : n e nthe center long ne edge , o rsc rewinghe str ip o he case , ndanother o the s ide of an ad jacen t dge o r a t t ach ing he bo t -tom pane l . o re he ho les n wos teps i th wo different rad-point i ts :one bi t s l ight lyarger han he d iamete r f he sc rewheads or ecess ing he as teners nd another i t s l ight lya rgerthan he diameter f the sc rew hanks o provide lea rance

h o l e s . T h e i d e r o l ew r l l l l o wo r m o v e m e n t . ) o s i t i o nhs t r ips n he ns ide ur face f a ra i l about inch rom t s oedge nd mark he posi t ions f the sc rew oles i th an awBore pi lotho le ora No. 8 sc rew t each marked oint , heuse a dr i l l i t te d wi tha screwdriver i t o fas ten he s t r ipsthe case above .ef t ) . fo nstal l he bo t tom anel , e t he caon t s back .Holdinghe pane l lush ga ins the str ips i th onhand, crew he bottom anel n place above, rght).

60



SHELVING

tf h. number ndplacement f shelvesI in a frame-and-oanel abinet ill

depend n the use ou have n mind forthe urniture. f the cabinet ill hold

books, or example, ou mayneed ewershelveshan f it will be he nlace or vourcomoact iscs.

eithough some helf-support ystemscan be put in place fter he cabinet sgluedup, a ittle advance lanningwillmake he nstallation asier. irst, hoosebetween ixed and stationary helves;each as ts advantages.

Fixed helves anadd o the structuralintegrity f a case, ut once nstalled heycannot e moved.One way o install er-

manent helves s o mount cleats n theframe nside he cabinet nd hen screwthe shelving o them. Fixedshelves an

INSTALLIGADJUSTABTEHELVES

1 Makinghe orner tripsI Rip board o a 4-inch-widthnd hen ut t o engh oreach rom op o bot tom nsidehe cabinet .ns ta l l dadohead n he adia l rm aw, e t t ing he bladeso a widthoaccommodatehe hickness f he shelf upports age 2)Star t ingt he end hat wi l lbe at he bot tom f he abinet ,cut a dado c ross he board or he owest hel f . l ide heboard lons he ence o cut he second ado t he next

also e glued nto dadoes outed n theframebefore he cabinet s assembled.

Whileadjustable helves o not addstrength o a piece f furniture, hey

allowgreater lexibility. s n simple ar-case onstruction, djustable helves recommonly held n place with woodendowel ins, lastic r metalshelf ins, radjustable helf tandards. he methodshown elow and on the ollowing agesuses orner trips and wooden upports.

Notched corner strips allow

shelf supports-and the shelvesthat rest on them-to be shift-ed easily o different levels.

shelf os i t ion.efore aking he ut , o make adoes hesame is tance oar t . rive screw nto he ence i th hehead f he astener gainsthe eft edge f he irst dado.Then ut he econd ado nd l ide he board long nt r lthe eft dge f hisdado s up agains thescrew ead. u tthe emainingadoesn his ashion abovd,hen ip heboardnto our qual t r ips .

6 l




r") Installinghe orner tripsZ Cut rabbet t he bottom nd oeach orner t r ipo allowt o si ton hbottom f he cabinet hile itting rothe ail .Tomount he strips, ore wscrew oles neach f hem ear heenMakehe holes n a dr i l lpress n a twstep rocedures or edger tripsnbottom f a cabinet page 0). Positieach trip na corner f hecabinet, aing ure hat he dadoes ace he nteor as shown.Mark he screw olesthe t i les sing n awl, hen ore pihole ora No. screw t each oint. a screwdrivero asten he strio o hecabinel lefl.

Insertinghe shelf upportsMeasurehe distance etweenhe

front nd back tiles n both ides f hecabinet. ut helf upportso i t he gapsbetween atching airs f dadoes. akesure hat he supports rewide nough obuttresshe shelves roperly,nd est-fitlhem right)o ensure hat hey it snuglyin he dadoes.

62



FRAME-AND PANELCONSTRUCTION

Cuttinghe helvingo itUse plywood r edge-glued oards

to make he helving,utting ach ieceosize n a able aw o hat he ends i l l

be lush gains the cabinet ides ndthe edges ill buttagainsthe stiles. ddedge anding o he vis ible dge fyouare using lywoodpage 9).To makeshelf i i ,set t on op of he corner t r ipsand ut l ine heir hape n he unders ideof he he l f . hen , ecure h e h e l f na v i se nd u t o u t h e corner s i thabacksaw right).Withedge-gluedhelving,youhave he opt ion f rout ing decora-t i v emold ing on tour l o n gh e ron tpd,oe< (c . tpn 5 )

f, Routingmoldingr.,f Place he shelves omentarrlynsidethe ab ine t , ndmark w o i n e s n hefront dge f each ne o ndicate he begin-nings nd nds f he moldings . rawth i rd ine o r he des i red ep th f cu t .P ro tec t ingh e she l f i tha w o o d ad ,clamp t to a work urface. i ta routerwi than edge-shapingit , hen et hedep th fcu t .Gr ipp inghe ou te r rmlywithboth ands nd esting ts base lateon he shelf , urnon he ool .Movehebi tp i lo t pagains the edge f he shelfand uidehe outer gains thedirect ionof ts bit rotationo cut he moldine

efil.

63



INSTALLINGATOP

T ike he bottom, he op of a frame-I: and-panel abinet s made rom hesame toik as he estof the piece, su-ally ndividual boards edge-glued ogeth-

er. To determine he size,measure heframeand add he width of any moldingyou plan o install under he ip. Alsotake nto consideration small amountof overhang t the ront and sides. Unlessthe cabinetwillbe eatured n the middle

of a room, make he op panel lushwiththe backofthe case.

Four common methods f attachingtops are llustrated elow One echnique

features abbeted locks. alledbut-

tons,"which it into a groove ut aroundthe op rails.Metal asteners anbe usedin the same way.Ledger trips, such asthose used o attach a bottom panel othe cabinet, will work equallywell or

securing op. Anothermethod callthe creation fpocket holes n thebefore he case s glued up.

Whatever pproach ou choose, ll

some lay n anticipation f wood mment; otherwise, he op will bucwarp and orce he rame apart. Aremember o installanydrawer-hanhardware page 2) before puttingtop on the cabinet.

TOP-FASTENING)PTIONS

Wood buttons Metal faatenera ?ocket holea Ledger ti lpa

WOOD UTTONS OLATCH)NA T(lP

1 Cutting grooven he op ails

I Fi ta router i th three-wingloting utter nd et he ool 's utt ingdepth or abouI3/tnch.Protectinghsurface f he cabinet ith wood aduse ar lamps o hold guide oarflush longhe edge n which he ouwil lbe iding;hiswil lprovidesurfato brace he ool as you ut he groovFor ach ail, uide he outer longhtop edge,movingrom eft o right leRepositionhe edge uide efore uttsubseouentides f he cabinet.

64



FRAME-AND- ANELCONSTRUCTION

r) Makinghe buttonsL youwillneed o produce series f 1-inch-squareuttons-at east hree oreach ide nd one orabout very inches orlargerops . ou an mass-producehese iecesrom singleboard, ut hoose tock f a hickness qualo he gap etweenthe bottom f hegrooveut n s tep and he op of he a i ls ,

less%o nch. u t 3/ r inch abbet teach nd f he board.Then ip he board nto - inch-widetr ips nd ut offthe ut-

tons bout % inches rom he ends lnsef). omake oles nthe buttonsor ns ta l la t ion,se 3/ro-inchbi tand corner igfashionedrom scrap f 3/rinch lywoodndL-shapedup-port rackets. lamphe ig o he dr i l lpress able nd teadythe buttons i th push tick. ore hroughhe enters f he

buttons n he unrabbeted ortionahove)

InstallinghebuttonsSet he cabinet op ace downon a work surface, ndposi t ionhe ase ps ide own n opof t .Al ignhe backof he cabinet i th he back dge f he op and enterthe case etween tssides. it he abbeted nds f hreebuttonsnto he grooven he ai l t he back f he cabi-net, os i t ioningne n he middle nd he other wonearthe ends . eave %o-inchap etweenhe ipped ndsof he buttons nd he bottom f he grooveo allow ormovementf hewood. r ive crews i th dr i l l to as tenthe buitonsn place left).

Wood button

65



FRAME_AND_ ANELCONSTRUCTION

Squaringhe oplns ta l l ba r l amo c ross he ron t f

the ase l i sn ins he harwi th he on trail .Using ood ads o ocus ressure

on he corners, utt ne aw f he lampon he edge f he op and he other aw nthe ront tile. o est or souare. easurethe gap betweenhe edge f he cabinetand he edge f he opat several ointson both ides. he ap hould e uniform.lf it is not, ighten he clamp right) nlilthe op s correct lyositronedn he ase.lnstallhe emaining uttons page 5),atleast hree er ide. he buttons n hesides hould e i rmly eated n he groove;the buttons n he ront-l ike hose n

the back-should e backed ffs l ight lyfrom he bottom f he sroove.

P()CKETOTES

1 Boringoles i th c ommercialigI Use dr i l l o bore oles n wo tepwi th wodi ffe ren t rad-po in ti t s : nes l i g h t l ya rgerhan he d iamete r f hescrew eads, o hey an be ecessed, ndone ittle arger han he screw hanksoa l low l i t t l emovement . l amo s toob locko a work u r face , hen i t he i r sb i ton he d r i l l .Wrap s t r ip fmask in

tape roundhe b i t o mark he d r i l l i ndepth. utt he op edge f an upper ail othe cabinet gainsthe top lock, nsidsurface p,and lamp commercial ockhole i g l o s eoone nd . o ld inghe a if rmly, ore he hole, topping hen hestrip f ape oucheshe ig.Reposit ionhjig o bore not her ole t he middle /efand hird ne ear he other nd. i t hsecond i ton he dr i l l ndbore he cleaance oles n he ame manner.

66



FRAME-AND_ ANELCONSTRUCTION

t') Aftachinghe opL Oncehe abinet as een luedup (page 9),set he op ace downona work urface, ndposi t ionhe

case ps ide own n t as ouwouldwhen nstalling ood uttons page65) . i Ia dr i l lwi th screwdriveritand r ive crews o attach he backrai l f he cabinet o he op /eff) .Squarehe abinetop he ame ayyouwould hen nsta l l ing ood ut -tons page 6), hen drive crewsth roughhe e m a i n i n ga i l s .

SECURINGT()PWITHLEDGERTRIPSInstallinghewood tripsCut our edger trips nd bore wosetsof holes n hem or mountingpage 0).To nstall he op, irst crew he strips nplace lushwith he op edges f he upperrails f he cabinet right).hen, set hetoo oanel ace own n a work urface ndplace he abinet n posi t ionn op of t .Screwhe oo o he strio ttached o heback ail and quare he op page 0. Runscrewshroughhe emainingedger trips.

Ledqer etrip

67





INSTALLINGMOLDING

PREPARINGNDNSTALLINGOLDING

1 .'hethel i t ss tore-boughtr shop-" '

rnade, noldi r rgulf i l l s key olefor the cabinetmaker. n a frame-and-panel abinet , t s pr incipal unct ion

is o hide he ointbetween he op andthe ails, reating he llusion f a seam-less onnection. utmolding lso ivesa piece f furniture a decorative nddistinctiveook.

By shaping he edges f a piece fhardwoodwith a router or-as shownbelow nd on he ollowing ages-witha table au you can ransform ome fthe same tock sed or he cabinet ntoattractive oidings. rown, ove, ead

and ogee urve re ust a ewof he com-mon profiles sed n cabir-retmaking.

Wren cutting he moldings, ake hefinaloass vervshallow ne at halfthe

speedof revioirr os.r. Such inishingtouch should produce smooth inishthat will requiie nly minimalsanding.

The rr old r g .fo ilt i s.fittt c- a r cl-pttrrcl ctltinet os ctft ort a taltle sttweryipped witlt o set f ogec rrives.

1 Cutt inghe molding na table a wI Select board ong nough o yieldmoldingsor wo sidesand he ront of he cabinet . f ter i t t ing ut a molding eadwith he appropriate ut ters , crew n auxi l iary ence o them e t a l i p e n c e . Wi t h h e m e t a l e n c e l e a r f h e m o l d i n ghead, osi t ionhe auxi l iaryence ver he able pening ndturnon he saw. rank p he head o cut a notch n he wood.Tosecure he workpiece, lamp eatherboardso the enceabove he molding ead nd o the saw 3[ls [s3r ino oainci

the edge f the stock. hen, a ise he cut ters s nch above hetable nd eed he workpiecento he molding ead. inish hepass i tha push t ick. or deeper ut ,make ddi t ional ass-es , a is ing he cut ters /ainchat a t ime. Repeat he procedureoshape he opposite dge f the workpiece above). nstall com-binat ion lade n he saw, hen ip he moldingrom he edgesof he stock. ut he moldingo en$h or one ide f he cab i -net , making 45 'miter at one end of he piece.

69



FRAME-AND-PANEL CONSTRUCTION

Q Tighteninghe lampsr-J Protectinghe opposite ide fthe ab ine t i th wood ads , ns ta l ltwoclamps crosshe op of he case.Tohold hemoldingirmly, laceheclampinglock etweenhe moldingand he wood ads . igh ten achclamp little at trme right)unIilthinbead f glue queezesutof heloint.Remove ny xcess dhesive.

r') lnstallinghemoldingnone ideL Cutfour ood ads nd woshorpieces f moldingo serve sspeciaclamping locks .urned pside ownthe blocks i l lmesh i th he moldinbeing luedn place. pply neven ayof adhesiveo he back f he moldinbeing areful ot o slop ny lue n htop edge. he decorativerimshoulbond o he ail s, ot o he opof hecabinet. osit ionhe molding n heside ail left),makingsurehat t buttsagainst he cabinet opand hat tsmitered nd s lush with he ront til

70



FRAME-AND-PANEL ONSTRUCTION

Ins ta l l ingoldingon he abinetront

Wi t h h e p i e c e fs i d em o l d i n gt i l lc l ampedo he cab ine t , e a s u r eh ewid th f he ron t f h e case . u tap i e c e f mold ing l igh t lyo n g e rh ant h i sw i d t h , a k i n g 4 5 ' m i t e r u ta t he end ha t w i l lbu t t g a i n s themoldinglreadynplace . oldhenewp i e c e n p l a c e n d s e p e n c i l t omark cut t ingine n he unmitered

end above),ngling ut rom he cor-ner. u t hepiece fmoldingo ength ,mak ing 45" mi te r n i n ew i t h o u rcutt ing ark. nce heglue or he idepiece as r ied , emovehe lamps ndinsta l lhe piece f rontmoldingpage70).Repeathe processo cut and nstallthe e m a i n i n gi e c e fmold ing .

llll .ltlll ltlll lIllll lltllr lli1lllll llrlll ]lJltl]11llt1HO?Tt?An alternalive mei'hodfor alamping n moldingoTooimVlify he lampinqoperalion,maKe woNriangular oodVado,

whichwil lenable ou ouoe C clamVs o holdlhe moldinq n place .Glue ebr ip f oandpaperlo the edqe of each padto Vrevenl t ' rom elipVinqwhen lampinq?reeourei e aVVl ied .

7 I





f n.rr.n.., a drawer s nothing moreI than a boxwithout op-a front,abach wosides nd abottom. ndividualexamples, owever, elie his simplicity.They un the gamut rom he modernkitchen rawer lamming hut on metalslides o the drawer f a well-madeVictorian esk hispering omewithanearlyairtight igh. he ormer softenan anonymous, nterchangeable nitwith a false ront. The atter maybe afinicky ndividual precisely it to anopeningn a particularpiece ffumiture,itsunique ace lending eautifrrlly iththe grainof the wood urrounding t.

Pulled pen, drawer eveals oreofis personality. ach f s five pieces ay

be cut romadifferentwood. he ront,which showsmost, s chosen or its

D

Sized o itbetuveen rooves ut nthe sides f a drmuer, plywoodbottom anel slides nto position.Thepanel will bottomout n a

groove n the ront and be nailed o

the back o secure t in place.

jamming r chattering. swith oinerymounting drawer ffers many hoices(page 7).Everymethodmust upportthedrawet reventt from ipping s tis pulledout and stop t as t slides

home. The perfect rawerwill glidenearly ut, hen hesitate bit; drawerstops page 5)prevent he unit frombeing nadvertently ulledall the wayout or pushed oo ar n.

Different ypes f furniture demanddifferentmethods fmounting rawers.In carcases, rawers an e side-mount-ed: grooves outed n their sides lideon hin strips f wood attached irectlyto the cabinet ides. hey can alsobesupported y a U-shaped ramewith

runners t the sides nd a rail at thefront.Here, hedrawer lides n he bot-species, olor ndgrain; he hinner ides or ongwear; hebackfor strengh; he bottom or stability.

Not only s he ront hemost isible artof a drawet t alsotakes he mostabuse. syouwilldiscovern the oinery ec-tion of his chapter page 6), eepingt attached o the sidesrequires durable, olidoint.Front-to-sideoints ange romthe utilitarian abbet oint to the handsome, and-cut alf-blind dovetail. he abbet s quickand easy o cut; producingthe dovetail an be an art orm n itself.

The oint between hebackand sides lso equires trength,

but t shows ess, osimplerointssuch s dadoes uffice.astly,the bottom slides nto grooves n the sides nd ront.A drawer's ost asic unction s o hold hings. But t must

also lip n and out of the piece f furniture ousingt without

tomedges f ts sides-a raditional echnique alled ottom-run. n frame-and-panel ases, rawer upports it on stripsattached o the rames nly.

Commercial etaldrawer lide unners-like hose oundon filedrawers-provide wheeled ide-mounting ption.One-half f thehardware ttacheso the carcase nd he otherhalf o the drawer ides. sed xtensively n kitchen abinet-work,meal slides an upport reatweight nd provide ccessto the verybackof the drawer.

Whethermeant o holdpajamas n a quicklymade hild's

chest r nightgownsn an heirloom ighboy, rawers ill forman ntegral artofmanyofyour cabinetmaking rojects. achofthe housands f times omeone pens ne of hese rawers,he or shewillbe eminded f hecare ou ook o build hem.

Set offby the simplicityof ametallic singJe-pullhandle,a solid wood drau,er lides moothly n and out of a rame-and-panel abinet. Grooves outed nto the drawer idesrun along upports ttached o the rame of the cabinet.

73





DRAWEROINTS

RabbetFor back-to-eide

jointa on moat draw'ers; alao etron4

enough or oininq hefront to the aidee f

reinforced with screweor naila; auitable or

aolid wood or plyvvood

Through dovetail1tron4, decorative ointfor any drawer corner;

end qrain of draweraidea can be concealedwith fal6e front; appro-pdate for aolid wood

but not plSwood

DRAWERS

Half-blind dovetailThe raditional ointfor connectin4 hefront to the aidea;

conceala end qrain ofeidea; euitable only

for aolid wood

DadoCan be uaed o

join the front to theaidea and the back

to the sidea; or aolidwood or plywood

Double dadoFor any corner ofematl, iqht-duty

drawer; conceala endqrain of aideo andfront; auitable only

for aolid wood

Drawerback

Drawer rontTypically hickerthan eidee, backand bottom; maybe covered by afalae front

Drawer eideJoined to frontand back withany of a varietyof ointe; qrooveahown mesheawith drawer alide

DRAWER-MOUNTINGETH(|DS

5ide-mountedWooden lidee acrewedto carcaae oide panelarun in 4roovee outed ndrawer sidea

Eot'tom-runDrawer slidea on rail and runneraaaembly. win enone at endaof rail are glued nto double mor-tiges cut into carcaae panelg:one ed4e of runnera a iabbetedand fita into groove ut into panele

Commeraial sliderunner5Metal alidea acrewedlo drawer aidee meehwith runnere acrewedto carcaae

75



DRAWERIOINERY

--"fr

'-,' he irst step n drarver-makings othink the process hroLrghron-r

beginning o end. The ,arious tages fthe operation re elated; he inisheddimensions f a draler front, forextrmple, an depend n the oinerymetl-rod ou choose. nd drawer ang-ing methods an nfluence he wayadrawer s br,rilt.

Once ou have ettled n the size fdrawer, hoose oinerymethod pnge75), method f hanging nd he sryle ffront yon will r-rse;hen size our stock.Cut he ront, backand sides o fit theopening, hoosing he ntost isual lyappealing iece or he ront.Thegrainof the drawer hould un horizontallywhen t is nstalled. ake ure hat hebest ide of each iece irces utward;mark t with an X asa reminder.

Not allthe parts f a drawer ndergothe same tresses. he ront akes hehardest eating,he sides ittle ess, heback ess till.Cabinetmakersake hisinto accourrt l-ren hey br,rild rawers.Many will plane he parts differentlydepending n how sturdy heyneed o

be.Thus, he ront canbe hicker han hesides nd he sides hicker han he back.

Woodworkers ften use differentjointsat different orners. he choicedepends ot merelv n he desired isualeffict,but also on the stresses he ointwillface. oint hat mightbe adequateto connect he sides o the back of adrawermaynot be strong nough o ointhe ront o the sides.

The following pages present anassortment fjoinerymethods. ome resuitable or ront-to-sideoints,others restrictlyor back-to-sideoints,while tillothers an be used t any corner. ou alsoneed o keep n mind he ype fwoodyouareusing. ome oints, uch s he dove-tailand he double ado, an be usedonlywithsolidwood,whileothers-therabbet nd he dado, or example-workeqrrallyellwithply.rvoodrsolid ood.

For he stronsest nd mostattractivejoint, choose he through dovetail ,whichcanbe cut quickly ndaccuratelyusinga jig (page 0).You can also awone by hand as you would o oin car-case ides pnge 7).Unless ou will be

installing false ront (pnge 7),ahblinddovetail pnge 2)nay be a bechoice. lso alled he apped ovthe half-blind ovetail oncealsheo r r i r r n f t h p c i d p cb ' " , ' ' " '

Rabbet nd ipped abbet oints77)areeasy o cut and arestrong noto use t any orner fa drawer, aularly f reinforced ith screws r nThe main difference etween hejoints s hat he drawer ront n a iprabbet oint overhangs he sides.result, he ront must be cut argerthe opening.

Simple o constmct, he dadodouble ado oints pnge 8)are dchoices or small, ight-duty rawThe double ado onceals ndgrrnaking t a visually ppealing ltetive o the dado.

Likeotheroperationsn cabineting,drarver-buildingemands ccurand patience. ake est oints o ftune your tool s and nteasllrembefore utting nto stock, nd periodly test-fit drawer o eusrlre t willfopening erfectly.

Diftbrettt.joints or diflbrerrt tu'p()sesA sinrple ado oiltt is suJficiert o.joirback o tlrc sides f n drat er. But the.freqtires n strortger.ioirrt-irt tltiscnsedoultledndo, also krtotvrt ts t concenldado-arrcl-tortgtrc.

76



DRAWERS

RABBETOINTSUsing dado ead n he able awOn your able aw nstal l dado head l ight lywider han he hickness f the drawer idesand crank t below he able . Attach n auxi l -iary ence and set he width of cut equal othe hickness f the s ides . urn on he sawa n d a i s e h e b l a d e s o n o t c h h e a u x i l i a r yfence. e t he cut t ing eight o no more hanone-half he hickness f the drawer ront.Tocut the rabbets , ut t he edge of the ronta g a i n s t h e e n c e . H o l d i n gh e w o r k p i e c ef u s h g a i n s t h e m i t e r a u g e , e e d t f a c edown nto he dado ead. lip he board roundand repeat he cut at the opposite nd (right).

LIPPED ABBETOINTSCutting ip n a drawer rontTo ut ipped abbets roundhe edges f a drawerfront,mark ines n ts ns ide ace o al loworan over-hang f at east% inch. lsomark he abbet epth nitsedges-up o one-halfhe hickness f hedrawerfront. ut he abbe ts n wo teps, irst otchingheins ideace f he ront , hen eeding he stock ntothe blade nend nd n edge. o make he i rs t u ts ,set he blade eighto he depth f he abbet . henfeed he tock nsideace ownnto he blade o cuta longhe markedines insef) . omake he emainingcuts, et he blade e ight o he width f he abbets .Al ignhe blade i th he marks or he abbet epth ,then ut t he ence gains t he stock. eepinghedrawerront lush gains the ence, eed t on endinto he blade o complete ne abbet. urn he boardover nd epeat o cut he abbet t he other nd left).Then eed he stock nto he blade n edge o cut herabbets n he op and bottom dges.





DRAWERS

/) Trimminghedado onguesL lnslall n auxiliaryence, hen marka cut t ing ine n he edge f he drawerfront o divide ne f he ongues n ts

ins ideace n hal f With he stock ushaga ins th e mi te r auge , n s i d e a cedown, l ignhemarkedinewith hedadohead. u t t he ence gains t he stock.Notch he ence page 7), hen set hecut t ing e ight o r im he half - tongue.Holdinghe drawerront irmly gainstthe gauge, eed t in to he dado ead.Turn he board round nd eoeat heprocedure t he other nd right).

Q Cutting atching adoesn her-,f drawer idesTo oin he drawer ides o he ront, uta dado ear he ront nd f each ide. he

dadoes eed o mesh ith he half-tongueson he ront. irst, et he cutting eight othe ength f he halftongues. oset hewidth f cut, butt he drawer ide gainstthe ron t nd se o e n c i lo o u t l i n eheha l f - tonguen he d r a w e r ide . l ignthemarks ith he dado ead, hen utt herip ence gainst he tock. oldinghe boardflush gainsthe miter auge,eed t intothe blades . hen eoeat he cut on heother rawer ide .

79



DRAWERS

THROUGHOVETAIL(|INTS

Cuttinghe ailsWith he ail board till lamped o he ig, oosen

the scale humbscrews.urn ver he inger ssemblyand lide t along he support rms ntil oth calesindicateheALLposition.oosenhe ock nobs nthe ide f he ig, owerhe inger ssemblyn h espacer oard nd ighten he knobs, aking uretheassemblys sit t ing quarelyn he pacer oard.Use pinboard s a guide o scribe ine crosshe

ta i lboard arkinghe cutting epth. hen,osi t ion

the outer n he ig, ts base late estrng n he in-ger ssembly,nd et he ip of he bit%a nch elowthe markedine. urn n he outer nd ui out hewaste etweenhe ails right). out rom ight o left,keepinghe ool latagainsthe inger ssembly.ur nthe board ver, ecure t to he igand ut he ailsat he other nd he same ay. ollow he same ro-cedureo cut he ails f he other rawer ide.

1 Setting p he outer igI Set p a routerig or utt ing ovetailsollowinghe mafacturer'snstructions.or he model hown, djustinghe aon a inger ssemblyutomaticallyets he proper idth orpins n he oppositeide f he ame ssembly. obegin,a piece f3/a-inchlywoodo it across he op of he igasspacer oard,hen lamp he board etween he igbody nthe inger ssembly. he pacer oard erves sa solid asefor he assembly nd elps educeear-out. ake ure hatassemblyock crews ace up; fthey o not, oosen he scathumbscrews,emovehe inger ssemblyrom ts supportand l ip t over. i t a router i th dovetail i t , hen et hescale n both nds f he inger ssemblyo he bi tdiame(inseil.ighlen he humbscrews. lamphe ailboard onthe drawer's ides)o he ig,outside-face

ut.Loosen

he oknobs neach ide f he ig , hen lly a ise he nger ssemblynd ighthe knobs. ay ut he ingers crossend of he ailboard o set he size spacing f he ails. eave few ingeon each ide f he ail board o keeorouter teady hen t is cutting. heshould e one inger t each dgethe board o make alf- tails. nceare atisfied ith hespacing-symmc a lor asymmet r ica l ,epend ingnpreference-tighten

he ock crews/

80



DRAWERS

Q Cuttinghepinsr-,1 Removehe ail board nd urn overthe inger ssembly.e t he pinscaleto he diameter f hedoveta i li tas n

step .Then it he outer ith straight-cutting it and lamp he pinboard-thedrawerront-to he ig,outside-faceut.Use a i l board ut ted gains t he pinboardo mark ine or he cutting epth.Place he outer n he igand e t hetipof he bi t%o nch elowhe markedline. ut ut he waste etweenhe pinsthesame ay ou outed ut he ails /eff).Then, emovehe pinboard nd es t - f tthe o in t . f the t i s oo igh t , o o s e nthe sca le humbscrewsn d l i d e he

finger ssemblybout e nch oward heback f he ig.Tightenhe humbscrews(belowlMake nother ass ith he routerto remove ore as te e tween he n-gers, est-ft the ointagain , nd makeany necessary djustments. nce ouare atisfied ith he it, urn he boardover, ecure t to he igand ut he pinsat he other nd. Cut he pinsat bothends f he drawer ack he ame av.

8 1



DRAWERS

HAIF-BLINDOVETAILOINTS

' l Markinghe pinboardI Markheoutsideaces f he boards ith nX.Then etacutting auge o about wothirdshe hickness f hepinboardand mark ine crosshe end, losero he outsidehan heinsideace above), djust he cutting auge o he hickness fthe tock nd cribe ine round heends f he oinboardsomark he shoulderine f he ai ls .Next, se dovetail quareto outlinehe pins nan end f he pinboard;hewide ar tof he pins hould e on he nsideace f he tock. here renostr ic t uidelinesorspacing ovetailins , ut ormost raw-ers, tart ing rth half-pin teach dge nd dding wo venly

spaced ins n between akesora strong nd ttractiveoint .To ompletehe marking,ecurehe pinboardn a vise nd sea rysquare nd penci lo extend he ines n he board ndto he shoulderineon ts nside ace right). ark he wastesect ions ith nXas you o.

The half-blind dovetail makes nideal oint for building drawers:

The aik on the sidepiece qre visibbut their end grain is concealed y

the drawer front. The oint can be cby hand, as shown n the followin

page5 or by a router n contbinatiowith a tenrplnte r a ig .

Tryoquare

B2



DRAWERS

r) CuttinghepinsZ. Secure ne in boardn a vise i ththe outs ide ace f he stock owardyou, hen ut alonghe edges f he pins

witha doveta i l aw, orking ourwayfrom ne oard dge o he other. Somewoodworkersrefero cut all he eft-handedges f he pins irst , hen l l he ight-hand dges . ) oldhe board teady ndalignhesaw lade ust o hewaste ideof he cut t ingine; nglehe aw owardthe waste o avoid ut t ing nto he pins .Use mooth, ven t rokes , l lowinghesaw o cut on he push troke. ont inuethe u t us t o h e h o u l d e ri n e , he nrepeato cut he pins t he other nd

of he board.

-) Removinshebulk f he waste<'r. , l Set he panel nside-face p on awork urface nd clamp guide lock oit,aligningts edgewith he waste ide oft h e s h o u l d e r i n e .S t a r t i n g t o n e e d g eof he stock, old he lat side of a chiselaboulrAanch rom he guide lock; thetool hould e no wider han he narrow-est par tof the waste ect ion. With hec h i s e l q u a r e o t h e a c e f t h e b o a r d ,

use a wooden mallet o strike t, scoringa l ineabout a- inch-deepnto he wastes e c t i o n . h e n o l d h e c h i s e l l a t s i d edown nd square o the end of the boarda b o u t % i n c h b e l o w h e o p s u r f a c e .Str ike he chisel o remove thin ayerof waste . ont inue nt i l you each hes c r i b e d i n e o n h e e n d o f t h e b o a r d ,then pare away any excess tep 4) .Repeat he process i th he remainingwaste ections.

B 3



DRAWERS

Final aringWorkins n one was te ec t ion t a

t i m e n r e s s h e a t s i d e f h e c h i s e, i , i v 'Y i

againsthewalls f he ection i th h

thumb f your efthand; i th our ighand, ush he chiselowardhe shoder ine, having wayhe ast l iverwaste left).f necessary,ap he chisgently ith wooden allet .

/ t l

f, Markingnd uttinghe ails.-,1Set ail board nside-faceD nawork urface. old ne f he oinboards

end-down i th t s ns ide ace l ignedwi th he hou lderine f he a i l board .Use penc i lo ou t l inehe a i l s n heta i lboard right),Ihenxtendhe ineson he board nd using ry square. arkthe waste rth s, hen utl ine he ailson he other nd f he boardhe sameway. emovehe waste s ouwould he ncutting ovetailoints orcarcase anels(nape 30) Reneat hp nrocedureor heother ai lboard.

84





DRAWERS

Q Gluingp he drawerr-,1 Before luing p he drawer, ecihow ouwill mount I (page 7), sincsomemethods equire ou o prepare

drawer ides efore inalassembly. hsand he urfaceshatwil lbediff icuaccess fter lue p.Squeeze ome lon he contactingurfaces f he oiand pread he adhesive venly ithbrush. ssemblehe drawer,hen rratwobar lamps na work urface ndthedrawer n hem, ligninghe drawsides i th he bars f he lamps. nstwomore lamps long he op of hdrawer nd wo more crosshe bacand ront. lace wood ad etweenhstock nd he clamp aws o avoid aring hewood. Do otplace pad nlipped rawerront, s t wi l lpreventjointsrom losing.)ightenhe clamjustenough o ully lose he oints /ethen use rysquare o check heththe corners re t r ight ngles.f theare ot , se bar lamp laced iagoly o correct he problem page 9) .Finishighteninghe lamps nt i l beof glue queezes utof he oints, heingas you o hat he corners re quaOnce he adhesive as ried,emovedr ied luewi th pa in t c raper. l idthe bottom anel nto lace, hen r iva ew inishrng ai lshrought and ntthe bottom dge f he drawer ack ofix t inposit ion.

ilflltllt lltlll lltlltllllli ifilll lll iulllllfililllll11HO? TI?Fixinga loooe drawer bottomIf a drawer bo|tom s looee, oeohop-made edgeoto^tighhen he it. Deqin y uoing t able oawNo ipa few hin otripe of wood rom a board, nqlingbheblade Noproduce ne narcow dge. hen, uI theelriVo nto smaller iecee.1eIthe rawer peidedownon a work suflace and nstall a wedqeinlo any qap between he bottrompanel nd he sides or fronLofT,he rawer. oaL he eLripowilhqlue, hen nserN heNaVered nd nlo Nhe ap; uo ea hammer o ap them enuglyin |o place. nce he qluehaodried,uee a wood chiselNooever ny part of Lhe wedqeeprotrudinq rom Nhe roovee,

B6



MOUNTINGADRAWER

|| here are probably as many draw-I er-mounting methods s here are

drawer oints. The technique ouselect s determined y the piece of

furniture in which the drawer will behoused: a frame-and-panel abinetrequires ifferenthanging methodsthan does a carcase. he followingpages onsider oth types ofcasework.

A drawer can be supported n oneof two ways: along ts sides or alongits bottom. As shown below and onpage 88, a side-mounted rawer hasgrooves outed n its sides efore glueup, a l lowing t to run a long sl idesattached o the carcase. side-mount-

ed drawer n a frame-and-panel ase(page 92) s held in place by the same

SIDE-M0UNTING:ARCASE

A side-mounted rawer s slid ntoa carcase or test-fitting.A lipped

front conceals he unners ndgrooves hen he drawer s closed.

system f corner strips and supportsused o install shelves.

Commercial lide unners page 3)offer another method or side-mount-

ing drawers n a carcase. lthoughmany purists egard hem as a pooralternative, ommercial unners areactually tronger han wood runners,making them ideal or drawers hatwillbear heavy oads.

A popular way o support a bot-tom-run drawer s by a system f run-ners and rails affixed o a carcase, sshown o n pages 0 and 91 . Somewoodworkers prefer o rout a groovein the carcase ides and nstall a shelf,

which serves ot only as a drawer sup-port but as a dust panel as well.

1 Cutting roovesn he drawer idesI Beforeinal ssembly, uta groovein he outsideace f each rawer ide.There re no igid uidel inesor hegroove idth, ut t should e ableto accommodatelideshatare argeenougho support he drawer. n yourtable aw nstall dado ead he amewidth s he groove. raw utting inesfor he groove idth n he middle fthe eading nd f one rawer ide;alsomark he depth f he groove-nomore han ne-halfhe stock hickness.But t he ines or he groove idthagains thedado ead,hen rank heblades p o he depth tne; os i t ionthe ip ence lush gainst he stockand make he cut. f the groove idthexceedshewidth f he dado ead,turn he board nd or end and makeanother ass. epeato cut he groovein he other rawer ide.

87



DRAWERS

r) Rippinghe drawer lidesI lns ta l l combina t ion lade n yourtable aw. Crosscut board o hat ts enghis a few nches horter han he wid th of

the carcase idepane l s . hen pos i t ionher ip ence o se t a cut t ing idth qua l o hewidthof he grooves oucu t n he drawersides sfep ), less /zzinch or clearance.Cut wo s l ides rom he edge f the board,us ing push t ick o feed he s tock n tothe blade nghD.SmooIh ne edge f thesl ides i th a hand lane o make ure ha ttheywil l es t ush ga ins t he s idepane l sof the carcase . Caut ion: lade uardremoved or clarity.)

/) Install inshe l ides<'r- . f Inse r t he drawer n to he carcasea n d h o l d t n p l a c e h r l e s i n g p e r- cto mark he oca t ion f the grooves nthe ront dges f he s ide pane l s . heuse a ca rpen te r ' s quare o ex tend hemarks cross he ns ide aces f thepane l s . o mount he sl ides , ore hreeho les or counte rs ink ingcrews; aket h e c l e a r a n c e o l e s l i g h t l y i d e r h a nthe screw hanks o allow or woodmovm e n t .H o l d i n gh e s l i d e s a c k r o m h efrontedge f the carcase etween hemarked ines n he s ide pane l s , c rewthem n place left). est-fit he drawerlf i t i s oo oose , dd shims nder hes l i d e s ; f i t i s o o i g h t , n l a rg e h egrooven he drawer ide . ou an a l sor e c e s s h e s l i d e s n h e c a r c a s e i d e susing lig (page 9).

BB



DRAWERS

DADO-ROUTINGIGFOR RAWERUPPORTSTo out a ser ies f evenly paceddadoes n he s ide anels f a car-case ordrawer unners, se heshop-madeigshown t r ight .Dimensionsepend n he s ize fthe carcase nd he spacing etweenthe unners.

For he ig,cut a piece f %-inchplywood s a base. Make t aboutthe same idth s he carcase idepanels nda few nches ongerhanthe gap betweenhe unners. etthe igbase n a work urface ndplace router n t near ne nd.Mark he screw oles n he outerbase late n he igbase; lso rawa spot irectly elow he ool's huck.Bore oles or he screws; ut a holebelowhe chuck ide noughoal low learanceor he outer i t .Screwhe igbase o he machine'sbase late nd nstall straight-cut-

tingbit he same idth s he dadoesyouwish o rout.

Next, uta spacer o it snuglynthe dadoes; ake t slightlyongerthan he width f he panels. crew

the spacer o he bottom f he igbase,makinghe distance etweenit and he outer it equal o he spac-ingyouwant etween he unners.

Touse he ig,clamp side anelinside-facep o he work urface.Set he igon he panel i th hespacer lush gainst neendof heworkoiecend he outer itat oneedge. rippinghe outer irmly,urnit on and eed he ool across hepanel o rout he dado; eep hespacer lush gainsthe panel. ur noff he outer, hen nsert he spacerin he dado, epositioninghe lamps,as necessary. out he next ado,s l id inghe spacer n he irstdado.Cont inue nt i l l l hedadoes avebeen ut, hen epeat he operationon he other ide anel .

89



DRAWERS

B0TT0M-RUN:ARCASE

1 Preparinghe ailI Crosscut board ong nougho

span he gap betweenhe side aneaddinghe hickness fone aneloalfor win enons t he ends f he ail.the win enons , a rk he ends f hs tocko dividetswidth nto ifths. hins ta l l dado ead ide nougho cuout he waste etweenwoof he maSet he cu t t ing e igh t tone-ha l fhth ickness f he pane l s . ex t ,ns taa commercialenoningigonyour atab le . l amp he a i l o he i gend shift he device idewayso align h

marks n he ai lwith he dado eadcu t he hou ldern he midd le f thothe board. omake he ut, push hefonvard,eedinghestock nto he blaMovehe ig o cut he houlders t houtside dge f he ail . urn he stoa roundo cu t he emain ing hould(lefi l .fhen ut he win enons t hother nd.

r) Chiselinghedouble ortisesI Uon he endof he ail against ach arcase ide anel tthe desired eight f he drawer ottom nd outlinehe mortis-es, Extendhe ines o he edge f he panels,hen butt he woworkpiecesace o ace o make ure he marks re t he sameherght. ocut he mortises,i rs t lamp panel o a work ur-face. hen, tart ingtan end fone utl ine, old mort is ingchisel quareo he ace f he panel nd tr ikehe handlewith wooden al le t . se chisel he a me idth s he mor-tise nd e sure hat he beveledide s acing hewaste. akeano ther u t% inch rom he i r s t . on t inuen t i l ou eachthe other nd of he outline, sing he chisel o ever ut hewaste o he equired epth. hop ut he adjacent ortiseand he double o r t i se n he o ther ane l he same ay.Tes t - ft he win enons : iden rdeeoen mor t i se i ththe h i se l . s ecu i red .

I

Tenoningi4

I

90



DRAWERS

llt lt lll lll llt llllll lll llrlll lllll lll lll llllll lll lll1HO? TI?Fixinga bowed drawer sideA bowed ide can ?revent,a drawer rom ol id inqproVerly: ohoV-madeqlu bl ck willco re t, heproblem. utthe blockeliqhtlynarcowerlhanNhe aVbetween he

bot tom Vanel ndthe botlom edqe of r,hedrawer ide. Vread oomeqlueon Nhe urfaces f Nheblock th at, co nLa t the d raw e ,Lhen butf, the piece of wood aqainet,Nhe bot lom panel and drawer eide asehown, enLerinq t beNween he ront' and back. nelall a clamVacro;o he mid,Ale f he drawer, iqhleninq Xunt i l he e ideoLraiqhtene uL,Once he qlue as dried, emove he lamp.

n Insta l l inshe a i l nd unners<'

r.,f Cut wo runners or he side panelso f h e c a r c a s e ; a k e h e m h e s a m ewidthand hickness s he rai land as

l o n g s h e w i d t h f h e p a n e l s , e s sthe width f he ai l .Cuta tongue n hemiddle f one edge f he unners boutonethird he width nd hickness f herunner. out matching rooven he car-case ide panels ; enter he sloton hed o u b l em o r t i s e o r h e w i n e n o n s(inseil. o mou nt he runners, rstborea s e r i e s f h o l e s o r c o u n t e r s i n k i n gs c r e w s : h e c l e a r a n c e o l e s h o u l dal low or wood movement . hen, tt h e a i l n t o h e d o u b l e o r t i s en o n e

side panel ndslot he runner nto hep a n e l .M a k i n g u r e h a t h e u n n e r sbut ted quarely gainst he ai l , crewi i i n p l a c e . e p e a t o m o u n t h e u n n e rto the other arcase idepanel . t hesame ime hat youglue up he carcase,spread ome dhesive n he rai l ' s wintenons nd he doublemort ises n hec i d p n a n p l c : n d f i i t h p i r i l n t n s p i h p r

The lamping etupor he arcase i l lholdhe ai l n place hi lehe lue r ies .



DRAWERS

SIDE-M0UNTING:RAME-AND-PANEt

Attachingorner trips nd upportsPreparehe drawer ides s youwouldto side-mounthe drawer n a carcase(page 7).Glue p he drawer,henholdi t at he desired eightn he abinet ndmark he position f tsgrooves n he stiles.To mount he drawer, se orner tripsand upports page 1).Make he stripslong nough o reach rom he op edgeof he cabinet o he bottom f he drawer.Rout dado cross he st r ips , l igningtwith he marks oumade n he t i les .Cut wo upports o it betweenhe dadoes,less re nch or clearance. old hecorner t r ips l u s h ga ins the s t i l e swithhandscrews,ining p he dadoes iththe position arks. it hesupportsn hedadoes,hen lidehe drawernto osr-t ion. t should ove moothlynd i tcentered nd eveln he opening.f not,loosenhe handscrewsndadjust heheight f he corner trips, s necessary(above). crewhe wood tripso he stiles.

The same system of corner strips andsupports for installing adjustable helv

in frame-and-panel cabinets an beused o mount a drawer. Before he coner strips are screwed o the stiles ofthe cabinet, hey are held n place withandscrews. his way, the drawer cantest-fitted n the opening and the stripcan be raised or lowered as needed. Onthe drawer slides moothly and is centered, he strips are fixed to the cabine

92



DRAWERS

C0MMERCIALLIDE UNNERS:ARCASE

1 Installinshe unnerst -

I l n s t a l l c o m m e r c i a ll i d e u n n e r sf o l l o w i n gh e m a n u f a c t u r e r ' sn s t r u c -t ions. The ype shown onsis ts f twoparts : unners hat a t tach o the car-case nd slides hat are screwed o thedrawer. o help posi t ionhe runners ,

cut a piece f1/ , r- inch

lywoodo f tbetween he bottom f the carcase ndthe bot tom dge f he runner. f thedrawer s direct ly nder shelf r hecarcase op, rim t/zinch rom he ply-wood ig o al low or clearance uringinstal la t ion, hen he drawer ust bel i f ted l ight lyo f t the wheels n to herunners . i th he carcase n ts s ide ,but t he plywood iece gainst he bot-tom of the side panel . hen place her r r n n p r o : i n q i t h p i i q s p t f i n o t h : r . k

f rom he ront edge f the panel oal low or he hickness f the drawerfront .Mark he screw oles n he sidep a n e l , h e n b o r e p i l o th o l e t e a c hp o i n t . c r e w h e u n n e r o t h e p a n e l(abovd. Repeat o fasten runner ot h o n t h o r c i d p n a n p l

r) Ins ta l l inghe l idesL l ,on he l ides n he drawer,hen es t j i t t in he arcase .l f hedrawers oose , him he unners ;f hedrawer inds , lanesome tock rom ts sides page 4).fhen et he drawer psidedown. osi t ionhe l ides nd mark he crew oles n he drawer.Bore ilotholes,hen crew he slides n place above),

l i l i l l i | l i l | l t l ll i l l i l i l l | l i l i l l l i i l i l l l l l l i i l i i l l l i l i l | i l rut ttl ut ul tu ui ru ru ir tu ui ul i.U ui lil ut ru u

?HO? TI??oeitioning ig- f ^ t ^ - t ^ , , a , , r a - r a ^ + | , , ^ O g i t i O n| v | | v | Y J v u v v | | v v v | J Y

commercia l l idee ndrawer ides, se aohop-madeig.Cuta rabbet n a ecraVboard; ake he

depLh f Lhe ab-bet , qual o thedeeired ielancebeNween he lideand he boI0om fthe drawer ide .Touoe he iq ,hold l uVaqainot he bottrom f he drawer ide asshown.Then el lhe s l ide nLhe rawer ide ,botLom dge buttedaqainot he ig , Holdinq he l ide and iq n place , arkNhe uewholee,Then ore iloLholee nd ecrewNhe lide o Nhe rawer.



DRAWERS

FINE.TUNINGRAWERIT

1 Planinghe drawer idesI Adrawer ay ind n a piece ffurnitureven fter horoughanding.lf the oo or bottom f he drawer ub sagainst art f hecasework,lane hetop sfep ). f lhe sides i nd, emovethe drawer ndmark ny hiny reason he sides-high pots hat can beshaved ffwitha hand lane. osecurethe drawerorp lan ing , l amp wideboard o a workbench ithone dgeextendingverhe side.Hang he draweron he board o hat he binding ide sfac ing p . Then l amp no ther oardto he workbench,utt ingt againsthedrawer; se bench og o keep he econdboard rommoving. rippinghe planewithboth ands, have ff he markedspotswithsmooth, ven trokes nghf).Test-ft the drawern ts opening er i -od ica l ly,l an inghe ides n t i l hedraweritsperfectly.

r) Planinghe op ofa drawer

l to hold he drawern prace, eri t on a work urface ndnail hree crboardso he able lush gainst he siand back f he drawer. rippinghaplane rmly, ake smooth ass n topedges f he drawer ides rom heof he drawero he back.Moveo hadjacent ide f he able o plane he edges f he ront ndback. est-fitcontinue laning nt i l ou re atisfiwith he t.

94



DRAWER TOPS

,\ s he name uggests, drawer topf1' controls ow ar a drawer an slidein or out. There are wo basic voesdepending n where hey re ocated'orr

a piece f furniture. nward stops replaced ear he backand keep drawerfrom beingpushed n too far.Outwardstops re nstalled ear he iont and pre-vent a drawer rom sliding n beyondcer ta in oint r pul l ing ight u t .

There s a drawer top or every ieceof furniture. nward stoDs re deal orcarcases i th s ide-mounted rawerssince heycan be mounted t any pointon the side anels. utward tops orkwell or anypiece, ut they aresimpler o

installon frame-and-oanel urniture.

OUTWARDTOPS: ARCASE

INWARD T0PS:CARCASE

Attaching n nward to pWitha band aw or saber aw ut a 1- o 1%-inch-diameter isk romapiece f scrap ood he same hickness s he drawer ides . ore n off-center ole n he stop, hen screw he disk o a s ide panel ear he back .Set he carcase n ts s ide and close he drawer. oosen he screw l ight lyand otate he s top unt i l t ust ouches he drawer, hen ighten he screw

1 PreparinehedrawerI

I Before luing p hedrawer,utanotch or he stop n he drawer ackwith able aw. Mark ut t ingines nthe middle f he op edge ora 1- inch-wide otch. e t he blade igh noughso ha t he no tch i l l l ea r h e topwhen ou nsta l lhe drawer. crewboardo he miter auge san exten-s i o n . l i g n i n gne f h e u t t i n gineson he tock rth he blade, utt hand-screw gainst heend f hedrawer ackand lamp t o he extensionsa s topblock. urn n he aw, o ld hestockf lush ga ins th eex tens ion ,n d e e dthe wo nto he blade. urn he work-piece round nd ut he other ide fthe notch. emovehe waste n betweenbymakingepeat uts /eff).

95



DRAWERS

r) Screwinghe stop n placeL Cuta drawer top roma scrap Doaro:m a k e t l o n g e r n d n a r r o w e rh a n h ewidthof the notch n the drawer ack. o

m o u n t h e s t o o . n s t a l l h e d r a w e r n dmark he ocation f he notch n he bot-tom of he oane l r she l f nder h ich hedrawer i l ls l ide . ore pi lot ole hroughthe stop, hen screw t in position rrghf),a l i g n i n gt s e d g e s it h h e i n e s n h ecarcase. o not ighten he screw l l heway.Wi th he ong dge f he s top paral-l e l o the drawer l ides , nstal l he drawer(inseil.Once he stop passes ompletelyth rough he notch, otate t 90 ' so tha t tslong dge s paral le l o the drawer ack.

()UTWARDT()PS: RAME-AND-PANELInstallingstop n he ront ailCuta drawer top rom scrap oard. tshou ld e ong nough o ex tend e lowthe ront ail f hecabinet hen ne ndisattachedo he ail . o mount he too.bore pilot ole hrought near ne nd.Wrth he cabinet opoff screw he stopto he middie f he ai l . eavehe crewjust oose nough o hat ou an otatethe stop ut of he way. nstallhe drawer.Once he drawer ack lears he ront ail ,rotatehe stop 0' so hat t extends elowIhe ail (right).



FALSE, RONTS AND HARDWARE

part rom theirvisualappeal, alsefronts have practical pplications

in drawer-makins. or he woodwork-er reluctant o diicard a drawer hat s

not perfectly lignedwith its opening,a properly mounted alse ront canprovidea simple olution. Centeringthe front on the carcase r cabinet,rather han on the drawer, ill salvagean imorecise it. False ronts can alsoserve s drawer tops, ut avoid exag-g e r a t i n g h e s i z e of the overhang .Slammins he drawer when t is filledwith wei[hty items isks splitting hefront as t strikes he cabinet.

INSTALLINGFALSERONT

Positioninghe alse rontInstallhedrawer,hen e t he cabinet n

itsback. ut he alse ront o he ight ize,hencarefullyower t intopositionright). nceyouare atisfedwith he placement,ress rmly;hepointed nds f he brads i l lpunch mpress ions ,a l lowingou o repositronhe a lse ront a terwhen ou ompletehe assembly.

A drawer ull puts he inishing ouchon a drawer with a alse ront.

Installins hardware n a drawer sthe ast-and possibly east axing-activity n an otherwise hallengingooeration. till.drawer handles nd

oulls need o be mounted with care.The key s o center hem on the draw-er front. Aligning a single-pull andleproper ly s fa i r ly straightforward:Mark the diagonals cross he frontand nstall he oull where he wo inesintersect . or a double-oul l andle .var ious ommercialigs can providefast and accurate ositioning. ut asshown on page 9, he ob can alsobedone usinga simple ape measure.

1 PreparinghedrawerI Once hedrawer as een roperly ounted,set t face p on a work urface nddrive wobrads nto he drawerront, eavingheir eadsprotruding. ake ure he brads re o t ocatedwherehedrawer ul lwi l lbe ns ta l led . hen nipoff he heads i th l iers .

97



DRAWERS

Q Gluingnd lampingr-,1Spread thin ayer fglue n heback f he alse ront. void pplyingtoomuch dhesiveryouwil lend upwith oomuch queeze ut.Place hefront n posit ion, i th he wo bradsres t ingn he i r mpress ions . o l dthe assemblyogether ithbar lamps;align he bars i th he drawer ides.Tightenhe lamps venlynt i lhereare ogaps etweenhe alse rontand he drawer.

llt ll] ll1lt lt llllltlltlltllllllllt lrilrfi lllr1HO? t?Faelening einqle-pull andleto a drawer already built,The crew upplied i th a oinqle-pull andlemay nol be ong enou4h o paoo hrouqha d,rawer if,h false ronl, )ne rem'edy oto countersinklhe crew,but tri tyou have lready soembled hedrawer, dril l may nol fi | inside,lnslead, work rom Lhe outside of thedrawer. Nart by boring clearancehole hrough he cenNere f Nhe alsefront and he drawer ront. Theneharpenthe houlder f a eVadebit elightly ider han he screw ea dto creaNe cuNtinaedae.Feedtheehank laf hebt throuqhlhehole{romtrheinside f he drawer ndatlach t t o Nhe rill. wtch on he ool and pullNhe ff, nwardyou uniil he countersinki nq ole o he righN epIh.

9B



DRAWERS

ATTACHINGDRAWERANDLE' l MarkingolesorscrewsI Place he drawer n ts back n a

work urface, hen mark er t ica l ndhor izonta lines cross he drawerrontintersectingt ts center. or he double-pul lhandle hown elow, easurehegap betweents wo mounting osts. hentransferhatdis tanceo he hor izonta lline,makingwomarkshesame istancefrom he center f Ihedrawer right).

r) AftachinghehandleL Bore learance olesorscrews t hetwomarked o in t s ,h e n app ly ha t -ever n ish ouhave e lected. omountthe handle hown, crew ne mount ingpost o he drawerront. lip he pull ntothe post, hen it the other ost n h epulland screw t to he drawerronl left).

99



\

, ft3

JI

I



I sa inepiece ffurniture ears,[ \ completion, he ast majortaskbefore inishing he wood softenconstructing ndmountingthe doors. projectwithin a pro-

ject,assembling door demandsthesame are s building he pieceit accompanies. othing s morefrustrating han seeing carefullycrafted abinet ffset y a door hatis warped r ill-fitting.

In addition o providing visu-al focus, oors erve he simplefunction fprotectinghecontentsstored nsidea piece ffurniture.One of the irst recorded ses n

DOORS

A brad driversecures strip of moldingto a door rame, sandwiching central aneof glass etween he moldingand a rabbet

cut nto the edge f the rame.

door wouldbe mostappropriateon a simple arcase, hereas ineperiodpiece ormally emandsframe-and-oanel oor.Glass oorsare a good choice or a china or

curiocabinet.Since ood s prone o swellingand warping, olid doors houldonlybe nstalled n relatively mallpieces ffurniture.Wth a argercabinet-a loor-to-ceiling utch,for example-a broad, oliddoor,such s he board-and-batten rtongue-and-grooveoor,would emore ikelyto buckle hanwouldaframe-and-panel, eneered-panelor glass oot whose onstructionabinetmakingf a door asa phys-

icalbarrier was he medieval umbrey, large abinet sedto protect ood rom vermin. he design f the doorwas rim-itive:a single iece f woodheld n place ith simple orgedstrap inges.

Today's oodworkers ave ar more choices han heircounterpartsrom he MiddleAges. his chapter ill exam-ine ive different oor ypes, ach with ts own visual ppealand application, anging rom he rusticboard-and-battendoor o the inelycrafted rame-and-panel odel.Youwillalso earn ow o build ongue-and-groove oors, lass oorsandveneered-panel oors.

Tosome egree, he design f a piece f furniture ictates

the ype of door you will installon t. A board-and-batten

is calculated o accommodate hangesn wood movementdue o shifting eat nd humidity evels.Another oint o ponder s he degree fprecision door

requires. flush-mounted oorpermits ittle margin or error.A gapas ittle as 7s nch can spoil he ook of an otherwisefinelyexecuted iece.Overlay oors, n the other hand, donot require he same xactness ince heyare designed oexceedhe size ftheir openings.

A vast ange fhardware s availableor doors fall types,from rustic ron hinges eminiscent f the aumbrey o finecast-brass inges or flush doors.Mostof these ccessoriescan e purchased ithoneof severalinishes,ncluding lack

or polishedron,antique rpolished

rass, nd chrome.

Aframe-and-panel oor s hung on a cabinetwith detachable abinethinges, hichallow hedoor o be easily emoved fter nstallation.

1 0 1



ANATOMYOFADOOR

[ frame-and-paneldoormaybebuiltfl, thesame ay asone ide f a rame-and-panel abinet page 8).Althoughthe door llustrated elow eatures tan-

dardmortise-and-tenons,oucanalsouse aunched ortise-and-tenons rcope-and-stickoints. he loating an-el n thecenter fthe doorcanbe aised,as hown, ividedntoapattern fsmall-er panels r inlaid.The ails and stiles

FRAME.AND-PANEtOOR

have n ntegrated olding ut ntothem; or added mbellishment, oumaychoose o cut an archor curve ntotheupper ail.

The ongue-and-grooveoor s apopular hoiceor modern, uropean-style urniture. t has tileswith groovededges hat accept enons t the ends fthe ails. The ails have rooves n heirbottomedges nd ongues n heir ops,

allowinghem o nterlock. houldwoodcontract nd he ails separslightly, he matching ongues agrooves ill hideanygaps.

Theboard-and-batten oor sassebledwithoutglue.Rabbets recut ntheedges f heboards, hich rehtogether y battens crewed crossback f thedoor.Wood lugs reusto conceal he screw eads. he gl

BOARD-AND.BAfiENOOR

TONGUE.AND-GROOVEOOR



door s essentially frame-and-paneldoor with a glass anel ather han apanel between he rails and stiles.Standard ortise-and-tenonointsare

shown n the doorbelow. hepiece fglass its n rabbets utalong he nsideedges f the rame; t isheld n place ystrips f molding.

Theveneered-panel oor eaturesframe oined o the panel. oconcealhe

GLASS OOR

DOORS

plate oints hatconnect hepanel o theframe, abbets re cut nto the nsideedges t he back f the rame. hepan-el hen its snugly nto the abbets.

Although door s always ade o fita piece f furniture, t does ot have obesized xactlyto tsopening, sshownbelow n the drawer-mounting eth-ods.A flush-mounted oorcanbe dif-ficultand ime-consuming o construct

because fthe fine olerances equiredto build and hang he door. Both ip-rabbeted ndoverlay oors reusuallysimpler o make.

The entire hickness f an overlaydoorprojects eyondhe rontofa cab-inet or carcase. he ip-rabbeted oorhas abbets utaround tsoutside dgesat he bad<so hatonlyapartof s thick-ness s exposed.

VENEERED.PAI{EtOOR

DOOR.MOUNTINGETHODS

h L Llueh-mounted Lip-rabbeted Overlay

103



FRAME-AND.PANEL OORS

I fiame-and-panel oor mparts tyleA to a piece ifurniturewithout sac-rificingdurability or strength. ts solidframe construction accounts or the

structural ntegrity.At the same ime,any one ofseveral tylistic ouches anbe added o make t more attractive.These ncludedesigning n arched op nilor, fthe door s arge nou$, dividing he

Like he rame-and-panel ssemblyused o build the sides ffurniture,the rame-and-panel oorfeaturesa sturdy rame of raik and stilesencasing decorativeloating anel.

panel nto smaller ections ith hzontal ross ailsand verticalmulli

Youcanbuilda rame-and-paneldthe same way you would constru

frame-and-panel ssembly, singeihaunched ortise-and-tenons r coand-stick oints page S).This secfeatures door assembled ith standmortise-and-tenon oints and ntegramolding.The irst step s to sizestock.Make he stiles equal o the doheight; he rails should be as ongthe width of the door, ncludingtenons t each nd, minus he stile wiThe tenons ypicallyare cut ab7+ nch ong.

MAKINGFRAME.AND.PANEL()OR

1 Cuftinghe enonsI Ins ta l l dado ead l igh t ly idethan he enon ength nyour ab lesaw. t t ach nd no tch n aux i l i a ryfence page 8),Ihen et he widthof cut equal o he ength f he enonto cut he enon heeks; djust hecutting eight o about ne-thirdhe

thickness f he tock. utt ing he ailagainst he ence nd he miter augefeed he stock ace down nto heblades. urn he ail over nd makethe same ut on heother ide f hetenon. hen epeat he orocess t heopposite nd of he rail (left, bove)andwi th he econd a i l . ocu t hetenon houlders, et he height f hedado ead t about /zinch.With hera i l lush ga ins the ence nd hemiter auge,eed heworkpiecedge

down nto he b lades . u rn he a i lover nd epeat n he other ide fthe enon. ut he enon houlders tthe opposite nd f he ail he sameway left,below). epeat he processwith he second ail. oadd ntegratedmolding, t a router i th he appropate bitand mount he ool n a routertable. ut longhe nside dges f herails nd t i les s ouwouldormakina veneered-paneloor page 13).

r04



DOORS

Readyinghe tilesBefore repar inghe st i lesor inal ssembly,out decorat ivetopped oldingfyouwish

(page 07) . henmark ine n he molded dge f each t i le hewidth fa ra i l wayrom heend f he board. i thhe able aw lade ngled t45 ' , a l ign he ut t ing dge ith he markand ut nto he molded dge; top he cut a t he point herehe moldingnds nd he ace fthe sti le egins. ext, l ice ff he s t r ip f molding etweenhe45" cutand he end f he t i lewi th band aw. hen, moothhe cutedge s ing he able aw. Movinghe ip ence utof heway, o ld he he t i le lush gains the miter auge nd l ide he tock ack nd or th long hemiter auge above,ight).Make ure oudo not ut nto he molded dge f he stile.

Moldinqprofile

r) Preparinghe ailsorglue pI Re.oue heauxi l iarvence ndadjus the blade ngle o45". Maketest ut n a scrap oard nd measure

the ut endwith combinat ionquare ,adjustinghe blade ngle f necessary.To set he width f cut, mark ine nthemolded dge fa ra i l he ame is -tance rom he enon houlder s hemolding idth . l ignhemark i th heblade here t exits he able pening,then ut t he ence gains t he a i l .Adjusthe blade eight ntil ne oothjustprotrudeseyondhe enon houl-der. omake hecuts , u t t he ar lagains the ence nd hold t f lush

againsthe miter augeo eed t mold-ed-edge ownnto heblade. epeatto cut he other nd of the ail left)andboth nds f he second ail.

1 0 5



DOORS

Cutting ortisesA l i g n r a , lw i t he a c h t i l e n d m a r k

the out l ine f he mor t i ses s youwouldwhen making frame-and-panel ssembly( n a o p

l Q ) l n c i : l l : m n r t , c i n o : t t : e h m p n f\ r e o e .

o n a d r i l l n r p q s e n d r ^ l a m n h p c . t i l p n f h p

f e n c e . e n t e r i n ph e m o r t i s e u t l r n e n d e rt h e c h i s e l n d b i t .S e t h e d r i l l i n g e p t h ot h e e n o n e n g t h , h e n m a k e c u t a L a c hend of he mor t i se e fore or ing u t hewaste n belween rrght).

f, Preparinghe rame ora panelr. . / Assemble he rai ls nd st i les . hen. 'o tec t rnghe s tockwithwood ads , se wo bar c lamps o hold he rame oge thers e c u r e l y. i ta r o u t e r i t ha % - i n c h h r e e , w i n g l o t t r n g u t t e rand mount he oo l n a rou te r able . Removehe ence nd sett l ' e rameon he able . djust he b r t ' s u t t ing ep th o cu t hegroove idway e tween he bot tom f he ra me nd he cdoc

o f h e m o l d i n g , r i p p i r rgh e b a r l a m p s i r m l y, u t t h e n s iedge f he rame ga ins t he b i t near ne corner, hen o ta ti t c lockwiseo cu t he groove longhe a i l s ndst i les abovK e e p h e r a m e l a to n h e a b l e s y o u e e d t n t o h e b i tlMake raised anel o f t the rame page 3) and hen disas e m b l e h e r a m e .

r 0 6



DOORS

fi Gluingp he oor.,1 Squeeze ome lue nto he mortisesin he st i les nd n he enon heeks ndshoulderst he ends f he a i ls ; l so pply

some dhesive n he contact ingurfacesof he miter uts n he a i ls nd t i les . onotadd any lue o he panel rooves .Then, ssemble he door nd et t on wobar lamps na work urface , l igningherai ls i th he bars f he clamps. okeephe clamps rom al l ing ver, rop ach

one n a notched ood lock. rotectinghe rame r th w o o d ads , i g h t e nh e

clampsust nougho ul ly losehe oints(riSht),hen use a try square o checkwhetherhecorners f hedoor re t ight

angles . in ishighteninghe lamps nt i lg lue queezesutof he oints , heckingoccasionallyhat he orners emain quare.0nce he glue as ried, se paint crapero remove ny emainingdhesive .

ADDINGECORATIVEOLDING

Cutting oldingnto he tilesIns ta l l mold ing e a d i t h u t t e r so m i l l he prof i l efyourchoice; bead esign s shown above,eft).Crankhe cutterso % inch bovehe able , enter ne t i le ver hem, hen ut the ip ence gains the stock.Mark he places n he able

inser t here he molding ead tar ts nd tops ut t ing. henmark he points neach t i le here he molding i l lbegin ndend . o r ach u t , o ld h e t i l e us t boveh em o l d i n gead ,a l igningtheront ut t inginewith he mark n he able nser t

farthestrom ou.Keepinghe stile gainst he ence, owerhestock nto he blades . nce he stock s lat on he able , eedi t forward hi le ress ingt agains the ence. l ide our efthand long he op of he t i le nd ook our ingers roundhefaredge f he able . nce he back ut t ing ine eaches hemark n he able nsert loses to you, i f t he t i le ff he cut-ters above,ight). or deeper ut, make s many asses snecessary,a is inghe moldingead /ainch ta ime.

Moldingprofile --.,

r07



SOLID-PANEL OORS

Q olid-paneloors fferhesame om-rJ bination fstrensth ndcharm stheir rame-and-paneimunteqparts.hissectioneatureswostyles:ongue-and-

groove ndboard-and-batten oors.Sizing tock or a board-and-battendoor sa matter f makinghe ength ftheboards qual o the doorheight;heircombined idth should oual he doorwidth.Dimensioningtockior ongue-and-groove oor equires aking heIength f the stiles he same eight sthedoor.Thewidthof the doorwillbe

the length of the rails-withouttenons-added to the width of the

In buildinga board-and-battensome woodworkers se wo horizo

battens nstead fthe standard -shaopattern; or added trength, hepieces re ecessed n dadoes ut ntback of the door. A more elabmethod is to rout a sliding dovacross he back and it the batten sly into it, securing he support piewood with a single screw n the ceofthe door.

A modern,European-style oor near eft) is assembledfrom raik and stiles hat nterlockwith enons nd ongue-and-grooveoints. For he more ustic board-and-battendoor far eft), boards re oined with rabbet oints rein-forced by battens crewed o the back of the door.

MAKINGTONGUE.AND.GROOVE(l(lR

1 Millinghe tockI Topreparehe ails nd tiles ouhave o cut a series fgrooves,enon

tongues. egin ysawinggroove

lone edge f each oard, xcept or bottom ail. nstall 7+-inch-wideadoon your able aw nd set he cuttheight t Vzinch. enter board dgethe blades,hen utt he ip ence gthe stock; lamp eatherboard o he forsupport. o cut each roove,eed stock nto he blades, ressinghe boagainst he ence far eft). hen uttenon t he ends f each ail he saway ouwouldora rame-and-pane(page

04),butdo not make he shoucut .Final ly,uta ongue longhe ngrooved dge f each ail, except or top piece. nstall ndnotch nauxilfence page B).Set he cutting eighVq nch, hen lamp ne eatherboarthe ence bovehe dado ead nd nsta second eatherboard n he able. oeach ongue, se push ticko eedrai l n to he dado ead. urn he boover o complete he cut (near eft).

r08



DOORS

r) Gluingp he doorZ fitthe parts f he door ogether,hen umber a c h a i l o h e l p o u

reassemblehedoor or rnal lue p.lf any oint s oo ight , se woodchise lo pare ome ood rom heedges f he enon r he groove, srequired. nce ou re atisfied ithhe it , ake he pieces part nd

s p r e a d ome l u e n h e e n o n s ,Reassemblehe door nd olace t on

wobar lamps, roppinghem pwithnotched ood locks. rotect-ing he stock ith wood ads, ight-en he clamps nt i l lue queezesfrom he otnls abovd. Once headhesive as r ied , emoveheexcess itha paint craper.

frame door may \f ,,\\\c a u o e r o e e - q r a i n \ \ ' : \ \ \ iscralchee on he raile.An eaey solution e Nosand Nhe aile ireL,NhenapVly t r ipe of maekinqLape o the ra i ls , l igningNhe dqe of the tape wiLh heioints belween he aile and,sIilee.

Theneand Lhe etilee.

llfllll lll lltlll IJllt lljlIl llllllllJrJll] llllllllllll1HO?Tt??reventingoanding

--6\S

ocrat'aheo1 a n d i n q t h esbilee f a eolid-

t Y -

N$



DOORS

BUILDINGBOARD.AND.BATTEN()()R

AssemblinghedoorDry-clamphe door nside-facepusing hesame etup s

fora tongue-and-grooveoor page 09).Then ut wo battensslightlyhorterhan he door idth ndnarrowerhan he doorboards. ositionhe wo pieces fwood crosshe op andbot-tom f heassembly.hen it anelect r icr i l lwi thcombinationbitand ounterboreolesorscrews ndwood lugs t 2-inchintervalslonghe battens, lternatingetweenhe op and ot-tomof each oar d. ake learance oles xceptn he places

1 Cuttinghe abbetsI On our able aw nstall dado

one-half swide s he stock hicknAttach nd notch nauxiliaryence48), hen et he cutting eight-agaone-halfhe hickness f he boardssecure he workpiece,lamp wo eaboards nda suooort oard o he absaw s shown. eed he stock nto hblades s ing push tick. hen l ipboard ver nd epeathe ut alongnlhpr pdsp (lpft ' l

where he screw ill oin he batten o an outside oor oarThen, oldinghe batten quareo he edge f he door, riin each crew above,eft).Cuta hirdbatten o it diagonabetweenhe wo alreadyn place nd crew t in position.concealhe crews, pply dab fglue o heir eads, heinsert lugsn he holes. ap hem n place ith woodemallel above,ight),Ihen se chisel o rim he projectinstubs lushwith he door urface.

1 1 0



f) opular eatures f arge abinets,I hutches, ndshelving nits, lassdoors re onstructed n much hesameway as rame-and-panel oors page

104).The rame sheld ogether ymor-tise-and-tenonoints; decorative old-ingadorns ts nner edges. hedifferenceis haton a glass oor he moldingsnotrouted nto he rame; nstead, rabbetis cut, hen a separate lass-stop old-ing s nailed n place. he advantage fthisdesign s hat he molding aneas-ilybe pried offshould he glass reak.

In arger ieces f urniture, he dooris oftendivided y horizontal ailsandverticalmullions nto several maller

GLASS OORS

panels, ach olding ts own pane. naddition o its aesthetic ppeal, hisdesignmakes he glass ess rone obreaking nd also heaper o replace.

Glass s available n various hick-nesses nd ypes. or door-making ur-poses, he most ommonly sed arietyis sheet r window lass, vailablenthicknesses p o % nch.

Glass oors olve heproblem fshielding he contents f a piece

of urniture rom dust while stillallowingthem o be dkplayed.

CONSTRUCTINGGLASS (l(|R

1 Cufting rabbet o hold he pane fglassI Clamp he rame o a work urface, sing wood ad orprotection.hen nstall 3/a-inch abbeting iton a router ndset he depth f cut o he combinedhickness f he glass ndthe molding. old he ool irmlywithboth ands hile estingthe baseplate n he rame ear ne orner, hen urn on he

router nd uide he bit nto he nside dge f he door.Movethe outer lockwise long he edges above,eft)unlil he cutiscompleted. quarehe corners itha wooden allet nd awood hisel above, ight).Make he cuts with he grain irst oavoid plittinghe rame.

1 1 1



DOORS

Routinghemoldinglns ta l l decorat ive oldinp i t on

router,henmounthe ool n a routeraChoose board ong nougho produ

the ength fmolding ou eed. o secthe stock, nstallwo eatherboardsn routerable-one ressinghe workptoward he ence nd one pressing odirectlybovehe outer.Here,he upfeatherboard as een emoved or claty.)Turn n he ool nd eed he wopiece nto he bitwhile eepinghe boflush gainsthe ence. inish he pausing push tick. epeathe tep oa second oldingn he opposite dof he workpiece left), hen ip he wfrom he stock ith a able aw. awmoldingo he properength, akingmiter uts t he ends f each iece.and t one iece ta ime ,mak ing uyou lignhe miter uts with he ornof he abbets.

Q F i n a l a s s e m b l yr. ,f Set he rame nd he glass n a work urface, hen place he molding n position.Bore pi lot o le ve ry inches s ing n elect r ic r i l l f i t ted i tha smal l f in ishing a i lwi th he head n ipped ff . Then r ive he b rads n p lace sing i ther hammer r abrad r iver.Wi th he hammer, o ld he mold ing lush ga ins t he rame f he door ;use a piece f cardboard o protect he glass above, eft) . o use a brad driver, nserta b rad n to he pi lotho le , hen pos i t ionhe aws nd igh ten he ock ing u t . Ho ld ingthe frame steady, queeze he aws o set he nail (above, ight).

t12



Since plywood s not affected byhumidiry no allowance as o be madefor changes n the size of the panel.Therefore, t does ot need o have bev-

el cut along ts edge o fit into a grooveon the rame. The plywood simply estsin a rabbet ut n the rame.

Thepanel of a veneered-paneldoor- with its ypically ark-

hued wood-offers a visual con-trast o the ighter-coloredrame.

r) Cutting rabbet nd izinghe tockL Cuta abbet ust as youwould o make board-and-batten oor page 10).Set he cutt ing eight t he h ickness f he panel ;hewidth hould e one-hal fthe tock hickness . lampeatherboardso he saw able o support he workpiece .Insert shim etween he verticaleatherboardnd he ence o keep he pressureoff he abbeted art f he stock. eed he workpieceood-face p nto he dadohead above). hen ut he rame ieces o size, making 5" miter uts at each nd.Dry-assemblehe rame, hen ut he panel o it . dentifyhe panel dges nd hei rmat ingrame ieceso help ou orrectlyssemblehe door orglue p.

VENEERE,D.PANE,L OORS

I s ornamental s he frame-and-A panel oor, he veneered-panel ooris much simpler o make. irstof all, tdoes not recuire mortise-and-tenon

joints. n fact, he rame adds o strenghto the door at all;the our sides re im-ply mitered t each nd. The assemblyis held ogether y biscuit oints ha taffix t to a plyvood panel, which servesas he structural ackbone fthe door.

The veneered lyuood is formed byup to nine pliesof thin veneer luedtogether. he outer skin s typically %sinch hick or hardwoods nd %o nchthick for softwoods.

'l Routing moldingn he rame iecesI Rip he our rame ieceso width,then rosscut hem l ight lyongerhanthei r n ishedength . i ta router i thdecora t ive olding i t , hen ns ta l l hemachinen a router able. or ach ut ,

feed he workpiece ood-face own ntoIhebiI abovd, sing featherboardobrace he stock gainst he ence nd apush t icko comple tehe pass .

MAKINGVENEERED.PANEL()()R

r 1 3



DOORS

Preparinghe rame nd anelforglue p

Mark ine crosshe oanel nd heframe ieces bout inches rom ac

edge nd at 6-inch ntervalsn betweDisassemblehe door nd l amp neframe iece o a work urface, rotectithe s tock i th wood ads. djust hdepth f cut on a plate oiner,hen etthe ool's ase late n he bottom f herabbet n he rame iece. ith suppoboard nder he orner o keep t levea l ign hegu ide ine n he oo lwi thslot ocation ark. oldinghe oinewithboth ands, ut a groove t eachmark left).Repeat or he other rame

pieces, hen ut he mating lots n hepanel he same ay.

Gluingp he oorOnce l l he slots ave een ut, lue p he door. et he rame ieces nd he panel

good-face pon a work urface nd queeze lue nto ach lot , nsert ing iscuits syou o.To prevent he wafers rom xpanding efore verythings put ogether, ssemblehe door squickly s possible,itting he rame ieces o he panel above,eff).Next, et he door ntwobar lamps na work urface. i thwood ads rotectingtherame, ightenhe clampsjustenough o close he oints. nstal lwomore lamps crosshe op of he door, lacingthem erpendicularo he irst wo. inish ighteningnti l lue queezes utof he oints(above, ight).Once he adhesive as ried, emove ny xcess ith a paint craper.

, , ,\

tr4



HANGINGADOOR

f ast n metals anging rom wrought-U iron o brass, oor hinges ome na wide array of styles o complementvirtuallv anv door. Most fit into one of

four basic ategories hown at right.Clock-case inges are best suited odoors hat overlay heir opening, om-monly used or flush-mounted oors,butt hinges ipically sit n shallow mor-tises ut nto the door and case. urface-mounted inges re dealfor mpartingan antique or rustic ook to a door.Concealed inges, uch as he Europeancabinet hinge, are completely iddenwhen he door s closed.

Before nstalling he hinges, ead he

manufacturer's nstructions egardinghinge lacement. fyou are workingwithfine woods, ap the stock or brassmachine crews fter drillingpilot holesto reduce he chance f splitting. spotof glue n the hole will improve heholding abilityof the screw.

INSTALLINGUROPEANABINETINGES

1 Attachinghehinge odiesI On our rillpress, nstall Forstnerbit he width f he hinge ody-typical-ly,35mm. e t he door u ts ide-facedown n he machine ' sable , hen l ignthe bitwi th ne f he wo marks orthe hinges .f you rehanging evera ldoors , lamp top locks gains theedge nd nd f he door. et he drillingd e p t h o he h i ckness f he h i n g ebody. o ld ing he door lush gains tthe stop locks, eed he bi t n to hedoor left), f youare working ith morethan ne oor, r i l l he other nes, oo.Then l ign he mark t he other ndof he door nder hedrillbit.Repositionthe stop locks nd ore he hole; epeatforany ther oo rs. et he door n awork urface nd crew he hinge odyin place nseil.

DOOR INGES

Cloak-caae hingeFivota on a pin, whichallowa he door to belifted off

Eutt hingeAvailable n ironor bra99

oprin7-mounted. Can be adjuatedafter inatallation to correat minormountinq naccuraciea

5utfaae-mounted hingeA decorative hingeinstalled on the outaideface offluah doora

European cabineb hingeCommonly sed n kitchen

1 1 5



DOORS

Q Hanginghe doorr-,1 Slide he arms nto he mount-ingplates ndscrew n place ight).Close he door nd heck ts oosr-t ionon he case. ou an adjustthe height, epth r ateral osit ionof he door y oosening r ighten-rng he adjustment crews n heh inse rms .

r) Aligningnd ttachingheZ- mountinglatesHave helper old he door n ts opeposit ion gainsthe case. xtend he

hinge rms o butt he mounting lateagainsthe panel. ark referenceinaround he plates, hen nscrew hemfrom he hinge rms. lace he platein posit ion n he panel nside he casand drive n he screws /eff).

1 1 6





DOORS

INSTALLINGLOCK-CASEINGES

1 PositioninghehingesI Set he case n ts back nd ix str ips f masking apeacross he corners f he door pening. lace mall andpa-

per hims n op of he pieces f ape, hen et he door nplace. nce ou re at isfedwith he posit ioning,ark hedoor orners n he ape i th pencil . ext , ut t he hingesagainst he edge f he door; se tape measure o makesure hat hey re qually paced rom he op and bottomof he door above). oldinghe upper alf f he hinge nplace, l ip ff he bottom alf nd he hinge in. henmarkthe screw oles n he door dse inscf)

r) Mountinghe hinges n he doorI Secure he door o a worn ur-facewithhandscrews nd lamos.then ore ilot oles teachmarkedpoint . oldhe op half feach ingesquare o he door dge nd crewtt in place right).

9andpaper t2,Hinqe

ww/pin-

1 1 8



DOORS

Q Hanginghe doorr-) Reassemble he hinge nd eposi-t i o n h e d o o r n h e c a s e . h e c k h a tthe corners f he door re ligned ith he

m a r k s n h e m a s k i n g a p e . H o l d i n gthe bottom alfof one of he hinges, is-assemble he hinge nd move he dooraside , hen mark he screw oles n hecase . Repeat or he other inge. orepilotholes, hen screw he bottom al fof each hinge o the case /eff,). emovethe shims nd ape tr ips , nser t he pinin the bottom artof the hinge nd henolace he door n he case .

ADDINGURFACE.MOUNTEDINGES

Mountinghe hingesWith he door ood-facepon a worksurface , os i t ionhe hinges n he door,m a k i n g ure ha t h e p i n s x tendus tbeyond he edge f he door. lso heckt h a t he h i n g e s re h e s a m e i s t a n c efrom he op and bottom f he door.Markhe screw oles n he door ithpenci l ,hen ore i lo t o les . c rew hehingeso he door. omount he hingesto he piece f urni ture ,et he ase nits back. o ld he door n he ase ndplace p iece fsandpaper e tweenhetwo o serve s a shim,With he hingepincentered ver he edge f he dooropening, ark he screw oles n hecase , o re i l o t o l e s n d dr ive nthe screws right).

1 1 9



,:qfrr*







LEGS

LEG-TO-RAILOINTS

Rail

Tenon

Rail

\ , " ,

LEGHARDWARE

NotchCUL n le7 tohold mount- , -inq plate \

Commercial ardware thop-made hardware

RailFlanqe of mounLtn7plaLe fite tnto groovecut near end

NotahCul; n le7to accePt \corner block -:

RailGroove cuLnear enda r r e n l a a n l i n e

' ' - : '

Mountingplate

Corner blockOroovee utin ende acceptepltnee

Hangerbolt

Spline

123



I l though ts origins an be racedA back o woodworkers f classicalt imes n China, Egypt, Greece ndRome, he cabriole eg has become

ubiauitous ixture of Western urni-turi in the past 200 years, he bestknown designs nclude he staid QueenAnne eg with its spoon-shaped oo tand he ornate all-and-claw oot ofthe American olonial esign. ue othe eg's widespread opularity, verygeneration as added ts own touchesor varied old ones, o hat there s nostandard attern. Designs ange romlegswith exaggerated urves o othersthat are almost nee-less nd virtually

CABRIOLE EGS

straight. he most common lement fcabriole egs s he S-shaped urve,whichis meant o suggest he grace nd ele-gance f a horse's eg.

The design hown below will yieldan attractive, ell-proportioned egstrong and stable nough o support apiece of furniture. You can alter hepattern o suit your own project orcopy he design fan existing eg hatappeals o you. However, o not exag-gerate he curves oo much or you riskmaking he eg unstable. efore ut-ting into the block of wood, performthis simple est on your design: raw astraight ine from the op of the eg o

the bottom; he ineshould fall withinthe leg outline atevery oint.

A cabriole eg.

MAKING CABRI()TEEG

1 DesigningcabrioleegI For emplate, uta piece fst iff ardboardrhardboardto he same ength ndwidth s your egblanks. odraw heleg, tart y outl ininghe post lock. ake ts ength qual othe width f he ai l hatwillbe attached o he eg; he widthshould e adequate o accept he enon f he ai l one-halfotwo{hirdshe width f he stock s ypical) . ext , ketchhetoe; or a leg of he proportionshown,t should eabout% to1 inch rom he bottom f he eg, hen raw curve n hefront f he eg rom he oe o he ankle sing rench urve;

a t t s narrowest oint , he diameter f he ankle hould eabout wo-fifthshe stock idth. Move n o he knee, ketchinga gentle urverom he post locko he ront dge f htemplate bout to 3 inches elowthe lock. hen oin heknee o he ankle i th relat ively traightine. ompletehoutl ine t he back f he eg, onnectinghe bottom f helegwith he back f he ankle. hen ketch curve rom heankle o he bottom f he postblock above). xperiment ithe outline ntil ouhave satisfactoryesign.

r24



LEGS

Illllll lt lll ll lltlli lt ll]li ll1iltlll l|l ]I1lll lltiIl1HO? Tt?Copyingt'he eei1nof a aabriole egTo Lransfer Nhe ontoure of an exieLinqleqontro temVlate, ee h is ehop-madeIrac in7 quide . UL 2- inch ube rom a

ocrap block, hen use your rable aw Notorm aV in one ed4e. aw off the bot|omhalf of Nhe wedqe. emove he atbrid4efrom a ball-point Ven nd uoe epoxy lueNobond t to Nhe ube uel Io one side of

r) TransferringhedesignI nme eg blankCut ut our empla te na band aw,then and he edges p o he markedout l ine . o ldhe empla te la t n one fthe ns ide aces f he eg lank, ak-ing ure hat he ends f he empla teand he blank re l igned nd hat heback f he oost locks lush i th heinside dge f he block f wood. racealong he edges f he emplate o out-

l i n e h e eg . u rn he b lank ve r ndrepeat he procedure n he other nsideface above). t his point, ome ood-workers refero make reparationsorthe oinery efore ut t inghe eg . l t seas ier o clamp nd u t a mor t i se n arec tangulareg lank, orexample ,hanto car ry u t he same roceduresn alegwi thpronouncedontours.) therwoodworkersut he eg irst and hendo he o inerv.

lhe Y; a?e Nhe arLrid^e o Lhe blockwhile heglue e dryinq. ouee Nhe uide , o ld he empla tef laLaqainoL ne eide ol the leg .Then, uide he penalonq he back and ronL of the leg, makinq ure heVoinL f Ihe V rides aqainot Lhe edge of the leg.

125





LEGS

4i Shaping nd smoothinghe eg\ ,1 To nish haping he cabr iole ega n d o r e m o v e n yb l e m i s h e s e f t b ythe band aw blade, mooth ts surfaces

witha spokeshave, ol lowed ya raspand sandpaper. n preparat ionor h i ssmoothing rocess , ecure he eg n ab a r l a m p n d x h e c l a m p o a w o r ksurface i th a handscrew nda C clampa s s h o w n . o l d i n g s p o k e s h a v e i t hboth hands t he op of a curved dgeof the eg, pul l he ool s lowly owardyou, ut t ing thin shaving nd ol lowingthe grain /eif).Repeat ntil he surfaceis smooth. urn he eg n he bar lampto c lean p he other dges . o smooth

an area hat he spokeshave annot each,use he rasp. he oolworks es t whenpushed iagonal ly cross he grain . in-ish he ob withsandpaper, sing rogres-s ively iner-gr i t apers nt i l the urfaceis smooth.

illl llllll ll ll lll ltl jllllll]lllllIllll ll1ll til l]llil9HO7Tt?Sanding a aabriole eg)mootrhing he curvedeurfaces of a cabrioleleg ueinq n ly aeheeL f eandpapero r a e a n d i n q l o c kr ieke rea l inq umpe rval leye r f laXlening ul

Ihe curves f excessive?ree6ure o apVlied , eeohoV-made a n d i n qVa dlhaL wil l o l low Nhe contoure oflhe leg. WraV a sheel of eandpa-

Ver around a thick oVonqe ha |you can comfortably qr ip andh o l d h e ? a ? e r round h e s p o n q e oyou emootrh he eg . Evenwilh i rm hand?reboure , here s no nek of overaandinq.

t 2 7



TAPERED ND OCTAGONAL LE,GS

f abinetmakers aper egs trict ly\-.r for visual effect.A taoer adds nostrength, ut neither oei t take an yaway. ts principal effect s o reduce he

stolid heaviness f a leg, mparting asleek ppearance o furniture as diverseas raditional English nd contemporaryScandinavian esigns.

A leg can be apered n one nsideface, n two outside aces, r, as llus-trated elow and on page 129, nall oursides. efore ettling n the amount oftaper or a leg-expressed n eitherdegrees r inches per foot-you canevaluate he visual mpact of the inished

product without cutting nto your egblank. Experiment ith different apersby simply masking ffthe part o be cutawaywith piece f ight-colored ard-

board. There reno prescriptions or theideal amount of taper, ut as a generalrule, he h icker nd onger he eg, hegreater he angle.

Another option well-suited o manyfurniture styles s the octagonal eg .Despite ts appearance f ntricacy, t iseasy o create singa able aw as shownon page 130.For either styleofleg, besure o sand he stock horoughly eforepreparing t for oinery.

Cut on a table saw

fitted with a mold-inghead and cut-ters, a bead profileadds a distinctivedecorative ouch tothis tapered eg.

'l Setting pand tarting he cutI Use cutt ing auge o outl ine he aper n he bottomend f he egblank inset) . henmark ines n he our acesof he stock ear he opposite nd o ndicate here he aperwi l lbeg in . ns t a l l c l amp n he o in te r ' sn feedab le o ho ldthe guard utof he way uring he operation. et he depth fcut or 7a nch nd, olding he blank gainst he ence, l ignthe aper tart inewith he ront f he outfeed able. utt

stop loc k gainst he eg s shown nd lamp t to heinfeed able. o start ach ass , aref l ly owerhe blankonto he utterhead hile oldingt rmly gainsthe encwith our efthand above). traddlehe ence ith our ighand, sing our humb o keep he blank lush gainsthstoo lock . ake ure oth ands re ver he nfeed idof he cutterhead.

J()INTINGTAPEREDEG



LEGS

ADDING ECORATIVEOLDING

Cutting oldingnto egOn our able aw nsta l l molding ead i th he appropr i -a te u t te rs ; bead rof i les shown. ark cut t ing ine oreachmolding none ace f he eg, hen old he eg gainstthe miter auge . or tapered eg, ouwil lhave o adjus tthe angle f he gauge. se carpenter 's quare o makesure hat he square art f he eg s perpendicularo hemiter lot .Crank he cutters o 7a nch bovehe able nda l i g n n e f h e u t t i n g ines i t h he mold ing e a d . h e n

r) Jointinghe aperL feea he es across he cutterheadwitha push tic-k,ushing own n het ra i l ing nd f he s tock h i le ress ing

it flushagainst he ence left).Keepyour efthand way rom he cutterhead.Make s many asses s necessary ntilyouhave rimmedhe stock own o hetaper utline, hen epeat he processoshape he emainingaces .

but t he ip ence gains the eg . o cut he irst molding,press he eg irmly gains the miter auge nd he ence ,whi le eeding he stock nto he cutters. epeat he cut onthe adjacentace , hen ont inuingn he samemanner nti lyou ave u t he molding nal l our ides . or deeper ut ,make s many asses s necessary,a is inghe molding ead7s nch t a time. Caution: lade uard emovedorclarity.)

'v-"at-"'

t29



LEGS

SHAPING N()CTAGONATEG

Cuttinghe egButt he stock gainst he ip ence

a ew nches n ront f he blade. djustthe cutt ing eight nti l ne ooth ustprotrudes eyond he ace f he work-piece. omake he rst ut , eed heblank nto he blade, traddlinghe encewith our efthand. otate he eg 0"clockwisend epeat he cut on he adja-cent ace. ontinuen his ame annerunti l l l he sides re ut

1 Settingp he utI Unplughe able aw, rank he

blade o ts highest ett ing nd djusthe cutt ing ngleo 45". Movehe ipfence o he eft-hand ide f he bladLay ne ace f he egblank n heblade i th corner esting n he awtable, hen utt he ence gainst hestock /eff.).

1 3 0



I dding nlay o a eg can ransformA an easily overlooked quare roctagonal lock of wood nto the eye-catching ocus of a piece f furniture.

Whether he goal s o create contrastwith the eg stock or to complementleg's utlines, ou can choose rom awidevarietyof nlay materials, ncludingmetals, ood veneers, arquetry nd-as shown elow nd on page 32-solidhardwood. ach voe of material an beprepared n the shop, ut most are alsoavailable n various iameters t finewoodworking tores.

INLAYSANDDETAILING

Standard ractice s o rout a groovefor an nlav rom he op o the bottom ofa eg. However, efore utting nto yourleg,hold pieces f inlayof different engths

up against t and select ength r arrange-ment hat oroduces he best effect.

Anothei decorative ption s o routa molding nto a eg. Although t doesnot stand ut as boldly as nlay,mold-ing can add ts own distinctive ouch oa oiece f furniture. ou can also nstalla molding cutterhead n your able sawand carve out a pattern, much as youwould on a door frame page 07).

An inlay of mar-quetry createsvivid counterpointto the understatedgrain pattern ofan octagonal eg.

ADDINGNLAVOA LEG

'l Cutting nd outing roovesI To cut a straight roove, se our able awwiiha dadohead he same id th s he nlay; e t he cutt ing eightos l ight lyess han ts hickn ess. ake cut n a scrap oardand es t he i t ; ad jus t he width nd u t t ing eight f heblades, f necessary. ext,mark line or he groove n heleading nd f he eg nd l ign t with he dado ead. u t tthe ip ence gains the tock, hen eed t into he blades(above,efil. o make groove ithmore han ne traight

cut , use router. tart y secur ing l l our dges f he egwi th top locks. hen nsta l l s t ra ight -cut t ingiton yourrouter nd et he cutting epth o slightlyess han he hick-ness f he nlay. utlinehe groove n he eg, hen djusthetool 's dge uideo al ignhebi twi th ne f he ines hat unacross he gra in . r ippinghe outer rmly, u t he groove,movinghe ool againsthe direction f bit otation. epeatocut he other rooves,hen quare he corners itha chisel.

1 3 1





LEGJOINERY

f his section eatures wo time-test-I ed methods or permanently oining

legs o the rails of a piece f furniture:the mortise-and-tenon oint and he

dowel oint. Two more contemporarywaysare also eatured; oth nvolveusingknock-down eg hardware-suitable orfurniture that must be aken apart andreassembled eriodically.

To some extent, he type of leg willdictate he way you oin it to the rails.You would be unlikely, or example, ouse a hanger olt to fix a cabriole eg oa fine rame-and-panel abinet. mor-tise-and-tenon oint would be a moreappropriate hoice.

There are several echniques or mak-ing the mortise-and-tenon. ou can usea able saw o cut he enons page 04);

The enon t the end of a rail i* snuglyin a mortise ut out of a square eg,creating sturdy, ong-lasting oint.

the mortises anbe bored with a router(page 0)or a drill press page 06).Yott,may also choose o use hand ools. Asshown belowand on page 134, enons ut

with a handsaw nd mortises hoppedout with a chisel re raditionalmeth-ods hat many woodworkers onsiderparticularly uitable or the cabriole eg.Whatever method you choose, hestrength f the oint will be enhancedby ts arge gluing area.

As a rule of thumb, he ength of thetenon should generally e about hree-quarters he thickness f the eg. Thetenon s typically about one-third asthick as he ail,but manywoodworkers

base he enon's hickness nstead n thewidth of the chisel with which heywillchop out he mortise.

HAND.CUTORTISE.AND.TENON()INTS

1 Cuttinghe enonsI 0 u t l i n e h e e n o n s n he a i l s , h e n ecure n e f h ew o r k p i e c e snd-upn a v i se . u t l ong the i n e s n h e e n dof he ailwitha backsaw; ilt the saw orward nd ut o heshoulderineof he enon above,efil.fhen ompletehe cutwith he saw evel. o emovehe waste rom he enon heeks,clamp he ail ace-up o a work urface, rotectinghe stockwith wood ad. ut lons he houlderine n he ace f he

rail; urn over he stock nd epeat he operation n he otherside bbove, ight).To ut away he waste n he edges f hetenon, ecurehe ai l nd-up gain nd aw long he edgesof he enon o he shoulderine , ina l ly,lamp he ai l dge-up and ut hrough he shoulderines n both dges f hera i l .Reoeato cut he enons t he other nd f he a i l ndat both nds f he other ails.

r33





LEGS

Gluingp he eg nd ai lSpread l i t t le lue n the mort ise

and on he cheeks nd shoulders f hetenon. i t he wo ogether, aking urethat he ops of the rai land he eg aref u s h . P r o t e c t i n gh e e g w i t ha w o o dp a d , h o l d h e o i n t o g e t h e r i t ha b a rc l a m p . l i g n h e b a r o f t h e c l a m p w i t ht h e r a i l , h e n i g h t e n t u n t i la b e a d fglue queezes ut of the oint .Once headhesive as dr ied, emove ny excessglue with a paint craper. epeat he pro-cedure o fas ten he adjoining ai l o the^ ' { i ^ ^ ^ ^ + { ^ ^ ^ ^ + + h n l a a a n d f n o l r r p t r nd u l d L t r i l L r d L U u r L l l t r 1 t r 5 u " -

the remaining egswith he other ai ls .

DOWELOINTS

1 Locatins nd orins owel olesl -

I in he a i lsFirs t ,mark ocat ion oints o r he dowelholes . o lding ne of he ai ls nd-up, e ta cut t ing auge o one-half he hicknessof the s tock nd scr ibe l ineacross hee n d o f t h e b o a r d .Wi t h h e g a u g e t as l rght ly ider e t t ing, tch wo marks nthe end of he rai l hat ntersect i th hefirst ine ighil.Io avoid plitting he stock,use grooved owels o more han one-halft h e h i c k n e s s f h e a i l s . i ta d r i l lp r e s so r an elect r ic r i l lwi tha bi t he same iam-e t e r a s h e d o w e l s , h e n b o r e h o l e teach ocat ion oint ; he depth hould es l ight ly ore han one-half he ength ft h e d o w e l s . s e h e s a m e e c h n i q u e obore he dowel oles t the opposi te ndo f h e a i l n d n h e o t h e r a i l s .

1 3 5





LEGS

C()MMERCIALEGHARDWARE

1 Preparinghe ailsT '

I Ins ta l l ommercia l ardware o a t tach ai ls o a leg ol -lowing he manufacturer ' s ns t ruct ions . or he ype hownin his sect ion page 3&, tes t assemble he eg, he ai lsand he mount ing la te , hen mark he ocat ion f he pla tef l a n g e s n h e a i l s . o c u t h e s l o t s o r h e l a n g e s , l i g neach markwiih he blade, hen but t he ip ence gainst herai l .Set he blade eight o the engih f he langes , ddingt / rcinch or clearance. eed he ai l n to he blade i th hemiter gauge /eff). Caution: lade guard emoved or clarity.)Repeat or he other ai l .Sl ip he langes nto heir lo ts ndmark he screw oles n he stock. ore i lo tholes t eachpoint nd hen screw he mount ing la te o the rai ls .

r) Preparing he egL Fust, ut a notch ut of the eg or hemount ing la te . tand he eg up and holdt h e r a i l - a n d - p l a t e s s e m b l y n o p o f t ,a l i g n i n g h e e n d s f h e a i l s w i t ha d j a -cent s ides f he eg. Mark diagonal ineacross he op of he eg along he mount-ing plate . Next , l ign he op of he pla tew i t h h e o p o f t h e e g a n d m a r k l i n ealong he bot tom dge f he pla te crosst h e n s i d e o r n e r f h e e g a d d i n g r / r "inch or clearance. o cut he notch, e tthe eg on a band aw able and r l t hetable o a l ign he blade i th he diagonall i n e . B u t t a b o a r d g a i n s t h e e g a n dclamp t to he able s a r ip ence. eedt h e e g n t o h e b l a d e o m a k e h e c u t ,t h e n l a m p s t o p l o c k n p l a c e o h e l pwith repeat uts righil.Complete he notchu s i n g h a n d s a w. e s t - a s s e m b l eh e e ga n d a i l - a n d - p l a t e s s e m b l y g a i n n dmark he hole n he stock or he hangerb o l t p r o v i d e d . i ty o u r r i l lp r e s s i t hab r a d - p o i n t i t a n d b o r e c l e a r a n c e o l ef o r h e b o l t u s i n g s h o p - m a d e - b l o c k

ltg (inseil.

r37



LEGS

Fasteninghe eg o he ailsInserthe crew-threadnd f he

hanger o l t n to he c lea rance o lethe eg. Unlike ther asteners, hang

bolthas wo ypes f hreads: crewthreads tone nd nd o l t h readsthe o the r ; t a l so a s o head . c renuts nto he bolt lhread nd nd ighen hem gainst ach ther ith wrencformrng temporary ead n he bolTightenhe boltwithone f he wrencto drive he screw hreads ompleteinto he eg, hen nscrewhe nuts rothe bolt . l ip he ai l-and-platessemover he bolt nd crew nuton t , maing ure hat he langes re n heir loKeepinghe opof he ai ls lush ithtop of he eg, ighten he nut (left).

SHOP-MADEEG ARDWARE

1 Cuttinghe orner lockI Toattach he ails o a eg sing hop-made ardware, irstmake corner lock. ipa piece fwood arrow nougho drive hang-er bolt hrough t into he eg. henmake 5 'miter uts t both nds. ext, ut groovesorsp l ines , h ich i l lhe lp o in he b locko herails . nstal l dado ead nyourable aw itha width nd utt ing eight qual o one-thirdthe hickness f he ails . crew board o hemiter auge san extension,hen lignhe mid-point fone nd f he block i th he blades.C lamp he b lock o he ex tens ion . u t twaste iece rom he miter uts gainst heworkpieceo serve sa stop lock nd lampit to he extension. eed he stock nto heblades, hen urn t over

nd ut hegroove

in he other nd right) . est-f i the blockaga ins t he a i l s , hen mark nd u t hegrooves. ext , uta splrne oreach roove.Plane he splines arefullyo make ure hatthey i t p rec i se lyn he match ing rooves ,rememberingo cut hem %e hort o allowfor learance. ormaximum trength, akesure hat he grain f he splrnes uns crosstheir idth, ather han long heir ength.

l 3 8



LEGS

r) Boring ilot nd learance oles(- lnsLall brad-point iton your rillpress ndmark he center f he ongedge f he blockora hanger olt. ecure

theworkpiecen a handscrew nd lampi t i n p l a c e s shown , i t h h e cen te ra l igned ith he bit .Then ore he hole .Next, ark woholes n each ide f heclearance ole nd drillpilot oles right),repos i t ioninghe blockn he handscrewas necessary.

Q Fasteninghe eg o he ailsr-J First , as ten he orner locko he ai l s :Spread ome lue n he groovesn he block ndthe ails,hen it he plinesnto he groovesn heb lock . r e s sh e b lock paga ins the a i l s o i tt he p l i n e sn to h e a i l s . hen , e e p i n ghe a i l ssnugly gains the block, crewhe block o herails lefil.Preparehe egas youwould or com-mercial ardwarepage 37), utting notch utof he op or he corner lock ndbor ing clear 'ance o le ora hanger olt .Fas ten he eg o hera i l s i th he bol t page 38) , l ipping washerbetweenhe nutand he orner lock. ightenhenuIbelow) ntil he eg nd ails t snuglyogether.

r39



GLOSSARY

A-BAnkle: The narrowest part of a cabri-ole leg, typically about two-fifths aswide as he widest part of the leg.

Auxiliaryfence: A wood fencescrewed o the metal rip fence of atable saw, usually to avoid accidentaldamage o the fence when the bladewill cut close o it.

Batten: A board screwed across heback ofa board-and-batten door toprovide reinforcement.

Bench dog: A pin that fits into a sloton a workbench to help keep a work-piece n place.

Biscuit joint See plate joint.

Biscuit A thin oval-shaped wafer ofcompressed wood, usually beech,which fits into slots in mating boardscut by a plate joiner.

Bow: A defect in lumber character-izedby an end-to-end curve along theface ofthe stock.

Brad driver: A locking pliers-like tooldesigned for driving finishing nails.

Brad-pointbit: A drill bit featuringa sharpened centerpoint and two cut-ting spurs; produces cleaner holesthan a twist bit.

CCabriole eg: A type of furniture egcharacterized y rounded contoursdesigned o imitate he graceful egof a eaping nimal.

Cheek In a mortise-and- tenon oint,the part ofthe tenon perpendicularto the shoulder.

Carcase: piece of furniture with abox-like construction; made romsolid panels.

Copingbit A router bit that cuts adecorative molding and a tongue atthe end or edge of a workpiece, allow-ing the stock o be oined to a boardwith a matching groove.

Crossgrain: A lumber defect appear-ing as an edge-to-edge curve, produc-1n8 a concave ace.

Cup: A lumber defect appearing as anedge-to-edge curve, producing a con-cave ace.

Cutting gauge: A marking tool fea-turing a handle, a fence and sharpcutting edge or scribing a line on aworkpiece parallel to its end or edge.

D-EDado: A rectangular channel cut intoa workpiece.

Double dado joint A method ofjoining wood at corners by meansofa tongue in each piece hat inter-locks with a groove in the other; alsoknown as a concealed dado-and-tongue oint.

Dowel center: A metal cylinder thatis inserted into a dowel hole to pin-point a matching hole in a matingworKprece.

Edge banding: Decorative veneerglued to the exposed edges ofa ply-wood panel in a piece of furniture.

Edge gluing: Bonding several boardstogether edge-to-edge o form a panel.

End grain: The arrangement anddirection of the wood fibers runningacross he width of a workpiece whenviewed from the ends.

FFace luing: Similar o edge luing,except hat boards are bondedtogether face-to-face.

Featherboard: A piece ofwood cutwith fingers or "felathers" at one enused n conjunction with clamps thold a workpiece against he fencetable of a saw or a router table.

Fence: An adjustable guide to keepthe edge of a workpiece a set distancfrom the cutting edge of a tool. Alsocalled a rip fence on the table saw.

Forstner bit: A drill bit with a razorim and cutters for boring perfectlyflat-bottomed holes.

Frame: An assembly of horizontalrails and vertical stiles: used to forma door or one side of a frame-and-

panel piece of furniture.

G-H-IGlass-stop molding: Decorativestrips of wood used to hold a paneglass n place n a door.

Grain: The arrangement and direc-tion of the fibers that make up wood

Half-blind dovetail Similar to thethrough dovetail joint, except hatthe pins are not cut through theentire thickness of the workpiece,thus concealing the end grain of thtail boards.

Hangerbolt A bolt with no head;one end ofthe bolt has screw threawhile the other end features machinthreads.

Haunched mortise-and-tenon:Similar to the standard mortise-andtenon, except hat one edge ofthetenon has a notch cut out ofit.

Inlay: A decorative strip of metal,hardwood or marquetry that is gluein a groove cut into a workpiece.

I.K-LKerf: A cut made in wood by a sawblade.

t40



Kickback The tendency f a work-piece o be hrown back n the direc-tion of the saw operator by a movingblade or cutter on a woodworking

machine r tool.Ledger trip: A short, narrow pieceof wood used o support he op andbottom of a piece f furniture.

Leg blank A solid piece of woodmade of several hinner boards ace-glued ogether; sed as he basis fafurniture leg.

M-NMiter gauge: A device hat slides n aslot on a saw or router able, provid-

ing support or the stock as t movespast he blade or bit.

Molding: Decorative trips of woodthat can be carved on a router ortable saw.

Mortise: A rectangular ole cut into apiece f wood.

Mortise-and-tenon oinfi A joinerytechnique n which a projectingtenon on one board its into a mor-tise on another.

Mullion: A vertical member betweenthe stiles of a frame; also calledmuntin.

O-P-ROgee bit A decorative outer bit orstationary saw molding head cutterthat produces an S-shaped rofile.

Plate oint A method ofjoiningwood in which biscuits of wood fitinto slots cut in mating boards.

Pocket hole: An angled hole boredinto the face of a workpiece and exit-ing from its top edge.

Push block or stick A device used ofeed a workpiece nto a blade, cutteror bit to protect he operator's ingers.

Rabbet oint A method ofjoiningwood n which the end or edge of oneworkoiece its into a channel utalong he edge r end ofanotherworkpiece.

Rail A horizontal member of aframe-and-panel ssembly; lso,board running across he front open-ing of a piece of furniture designedto support a drawer.

Rail cutter: See oping bit.

Raised panet A piece of wood thatfits nto grooves ut into the nsideedges f a frame-and-panel ssembly.Beveling he edges fthe panel cre-ates he llusion hat the middle por-tion is "raised".

S-T-UShoulder: n a mortise-and-tenonjoint, the part ofthe tenon perpen-dicular o the cheek. n a dovetailjoint, the valleys etween he pinsand ails.

Spline A small piece of wood that fitsin mating grooves n two workpieces,reinforcing he oint between hem.

Spokeshave: plane-like hand oolwith an adjustable utter or shapingcurved surfaces.

Squeeze ut The excess lue hat isforced rom a glue oint when clamp-ing pressure s applied.

Sticking bit A router bit that cuts adecorative molding and a groove atthe end or edge of a workpiece, llow-ing he stock o be oined o a boardwith a matching ongue.

Stile: A vertical member of a frame-and-panel ssembly.

Stile cutter: See ticking bit.

Stop collar: An electric drill accessorythat fits around a bit to stop a drillingoperation t a certain epth.

Tearout: The endency fa blade orcutter o tear he fibers of the wood tis cutting, eaving agged dges n theworkpiece.

Tenon: A protrusion rom the end ofa board hat its nto a mortise.

Three-wing slotting cutter: A router

bit designed o cut a groove.Through dovetail oint: A method ofjoining wood at corners y means ofinterlocking pins and ails; he namederives rom the distinctive hape utinto the ends of oining boards.

Tongue n a tongue-and-groove rcope-and-stickoint, a protrusionfrom the edge r end ofone boardthat fits into the groove n another.

Twin tenon: Two enons at the endof a board hat fit into two side-by-side mortises.

TWist:A lumber defect characterizedby uneven or irregular warping.

V-W-X-Y-Z

Veneered aneh A panel with a thinlayer of decorative ood aid ontoor over t.

Wood button: A small, square-shaped lock with a rabbet at oneend hat fits nto a groove; sed osecure he top of a piece of furniture.

r4l





Face-gluing, 2lFrame-and-panel construction, 58 ,

59, 107

HHalf-blind dovetail oints, 75,76, 82-84Hand-crafting:

Dovetail oint s, 27-32, 82- 4Mortise-and-tenon oints, 133-135

Handscrews, ront endpaperHardware:

Doors , 0l , 115-119Drawers, 4

pulls and handles, 7, 99pulls or drawers lready uilt

(Shop ip), 98slide unners, 3,75, 7,93

Legs, 21, 22, 23, 37- 39Metal o p fasteners, 4

Haunched ortise-and-tenon oints,

46,47, 8-50Hinges, 07, 115-119

I-I-KIngersoll, an,6-7Inlays:

Legs, 20, 31-132Invisible ailers:

Shop Tip, 34figs:

Drawer lide unnerspositioning igs or slide unners

(Shop ip), 93Drill presses

pocket hole igs, 68

Routersdado-routing igs or drawersupports, 9

Shelf-drilling igs, 4lTable saws

raised anels, 5foinery:

Plywood, 7,18-19, 13See lsoDado oints; Dovetailjoints; Mortise-and-tenon oints;Plate oints; Rabbet oints

lointing, 3

LLedger strips, 47, 60, 64, 67Legs, 2l

Cabriole egs, 21, 122, 124-127copying he design fa cabriole eg

(Shop ip), 125sanding cabriole eg

(Shop ip), 122Decoration, 28

inlays, 20, 131-132moldings, 128, 29, 3l

Detachable egs, 2l, 122, 23,137-139

Joinery, 2l, 122, 123, 133-139Octagonal, 28, 130Tapered, 28-129

Lipped rabbet oints, 76, 77Lumber. SeeWood

M.N-OMiter gauges, 4,52Moldings:

Frame-and-panel onstruction , 7,69-71

Glass oors , 01, 11-112See lso Decorative echniques:

moldingsMoore, Terry, 10-11Mortise-and-tenon oints:

Frame-and-panel onstructi n, 46, 47,48- 50, 9

Hand-cut ,133-135L e g s , 2 2 , 2 3 , 1 3 3 - 1 3 5

Nails:Concealment

invisible nailers Shop Tip), 34

wood plugs, 5Octagonal egs, 28, 130

P-Q-RPanels:

Carcases, 8Frame-and-panel onstruction, 5,

46,53raised anels, 3-54, 5, 56

Veneered-panel oors, 103,1 3- 14See lso Edge-glued oards

Pipe clamps, ront endpaperPlaning, 3Plate oiners, 6Plate oints, 16, 17, 19, 6- 7

Veneered-panel oors, 103, 13, 114Plywood:Edge anding, 9-40Joinery, 7 ,18-19, 13Veneered-panel oors, 103, 13- 14

Pocket holes, 64, 66-67, 68Power ools:

Belt sanders, 5, 57Drill presses:

Pocket ole igs, 68Platejoiners, 6Safety recautions, ront endpaperSee lso Routers; Table saws

Pulls and handles, 7, 99Singlepulls for drawers already uilt

(Shop Tip), 98Quick-action clamps, ront endpaperRabbet oints:

Carcases, 9,34-35Drawers, 5,76,77

Rip ences, 14Ripping, 14Routers:

Dado-routing igs or drawer up-ports, 89

Dovetail oints, 80-81Raised anels, 6Shop-built miter gauges

(Shop ip), 52

SSafety recautions, ront endpaperSanding, 5

Cabriole egs Shop Tip), 127Frame-and-panel onstruction, 7Preventing anding cratches

(Shop ip), 109Screws:

Concealmentinvisible ailers Shop Tip), 3awood plugs, 5

Shelf-drilling igs, 4JShelves, 8-19,41-43

Adjustable, 1 42, 6 -63Edge anding, 9-40Frame-and-panel abinets, l-63

Shop Tips:Carcase onstruction, 1, 23, 26, 32,

33,34,40Doors, 109Drawers, 6,91,93,98Frame-and-panel onstruction, 2, 71Legs, 25, 127

Slide unners, 3, 75, 87, 93Spring lamps, ront endpaperSquare onstruction:

checking, 3, 59Surface-mount inges, 15, 19

T-U-V-WTable aws, 4

Raised anels, 3- 4, 55Tapered egs, 28-129Through dovetail oints, 27-32, 75, 76,

80-81

Tongue-and-groove oors, 102, 108- 09Preventing anding cratches(Shop ip), 109

Tools:Cl,amp , r ont endp p erSafety recautions, ront endpaperSee lso Power ools

Trigger clamps, ront endpaperVeneered-panel oors, 103, 1 3- 114Web clamps, ro nt endpaperWood:

Anatomy of aboard, front endpaperDefects, 2Face-gluing,121Grain

carcases, 7,20Preparation fstock, 12, 13-15Selection, 2

carcases, 0legs, 21

Shrinking nd swelling, 01T1pes, ack endpaperSee lso Panels; lywood

Wood plugs, 5

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ACKNOWTEDGMENTS

The editors wish o thank he ollowing

CABINETMAKING TECHNIQUESAdjustable Clamp Co., Chicago, L; Delta nternational Machinery/Porter Cable, Guelph, Ont.; FreudWestmore ools, Ltd., Mississauga, nt.; Hitachi Power Tools U.S.A. td., Norcross, GA

CARCASECONSTRUCTIONAdjustable lamp Co., Chicago, L; Delta nternational Machinery/Porter able, Guelph, Ont.; Freud

Westmore ools, Ltd., Mississauga, nt.; LeeValleyTools Ltd., Ottawa, Ont.; SandvikSaws nd Tools Co.,Scranton, A; Sears, oebuck nd Co., Chicago, L; Steiner-Lamello .G. SwitzerlandiColonial awCo.,

Kingston,MA; Veritas Tools nc., Ottawa,Ont./Ogdensburg, Y

FRAME-AND-PANEL CONSTRUCTIONAdjustable lamp Co., Chicago, L; American Tool Cos., incoln,NE; Delta nternational Machinery/Porter

Cable, Guelph,bnt.; FreudiVestmore ools, Ltd., Mississauga, nt.; LeeValley Tools Ltd.,Ottawa, Ont.;Richards Engineering Co. Ltd., Vancouver, BC; Sandvik Saws nd Tools Co., Scranton, PA; Sears, oebuckand Co., Chicago, L; Shopsmith, nc., Montreal, Que.; Stanley ools, Divisionof the Stanley Works, New

Britain, CT; Vermont American Corp., Lincolnton,NC and Louisville, YDRAWERS

Adjustable Clamp Co., Chicago, L; American Tool Cos., Lincoln, NE; Belwith nternational, Grand Rapids, MI;Delta nternational Machinery/Porter able, Guelph, Ont.; Freud Westmore ools, Ltd., Mississauga, nt.;

Hafele Canada, Mississauga, nt.; LeeValleyTools Ltd., Ottawa, Ont.; Leigh ndustries td., Port Coquitlam,BC; Mohawk FinishingProducts nc., Amsterdam, Y/Montreal, Que.; Sandvik Saws nd Tools Co.,

Scranton, A;Sears, oebuck nd Co., Chicago, L; Stanley ools, Divisionof the Stanley Works, New Britain,CT; Vermont American Corp., Lincolnton,NC and Louisville, Y

DOORSAdjustable Clamp Co., Chicago, L; Delta nternational Machinery/Porter Cable, Guelph, Ont.; Freud

Westmore ools, Ltd., Mississauga, nt.; LeeValleyTools Ltd., Ottawa, Ont.; Mohawk FinishingProductsInc., Amsterdam, NY/Montreal, Que.; Richards Engineering Co. Ltd., Vancouver, BC; Sears, oebuck nd Co.,Chicago, L; Shopsmith, nc., Montreal, Que.; Stanley ools, Division of the Stanley Works, New Britain, CT;Steiner-Lamello .G. Switzerland/Colonial awCo., Kingston, MA; Vermont American Corp., Lincolnton,

NC and Louisville. KY

LEGSAdjustable lamp Co., Chicago, L; Anglo-American nterprises, orp., Somerdale, f; Delta nternational

Machinery/Porter able, Guelph, Ont.; Freud Westmore ools, Ltd., Mississauga, nt.; LeeValley Tools Ltd.,Ottawa, Ont.; Richards ngineering o. Ltd.,Vancouver, C; Sears, oebuck nd Co., Chicago, L; Vermont

American Corp., Lincolnton, NC and Louisville, Y

The ollowingpersons lsoassisted n the preparattonofthis book:

Renaud oisjoly, orraine Dor6, Graphor Consultation,Josde aperridre, G€rard Mariscalchi,

Jennifer Meltzer, James h6rien

PICTURE CREDITS

Cover Paul McCarthy/Au Puits de Lumiire6,7 Paul Rocheleau8,9 Robert Holmes

l0,ll Thomas Ames, r.

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Documents

The Art of Woodworking - Cabinetmaking 1992