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AMERICAN WOODWORKER ▲ APRIL 19 9 8

Bevel the Fronts

Now you're ready to bevel the front of each level on the tablcsaw. Set your miter gauge to 30* and the blade to 26* from vertical (64# to the table). (See photo, above right.) Run each tray through the blade upside down, with the blade tilting away from the fence.

Start with the base, and bevel its front so that you shave just Vjg in. or less off the bottom edge of the front.

The rod is your alignment tool for laying out the remaining bevel cuts. Insert the rod into the base and stack tray #2 onto the base. The bevel on tray #2 should begin at the top of the base bevel. Mark your cut, cut the bevel on tray #2, and then repeat the process for successive trays.

Sand the Faces Flush

Stack the five trays together on the rod, lay the box on one side, and tape the front with masking tape so that the two sides stay fairly flush. Then sand each side flush and smooth on a stationary belt sander, with the platen set 90* to the table. (Sec photo, right.) I start out with 80-grit sandpaper and work my way up through 180 grit.

Sand the beveled face of the assembled box last, again using tape to keep the trays aligned. If possible, tilt your sander's table 26*. Otherwise, use a 26* ramp to hold the box at a 64* angle to the belt. Getting the face nice and flat requires patience, so go slowly.

I fine-sand all five trays, but I'm careful not to round over their crisp top and bottom edges. Then I apply two coats of 1 V^-lb.-cut shellac, followed by a coat of 2-ib.-cut shellac, sanding between coats with 320-grit paper. Carefully avoid getting finish on the rabbets along the bottom edges of the four lower trays.

Installing the Bottoms

Determine the dimensions of the five tray bottoms individually, by measuring from the shoulders of the rabbets. They should fit into the rabbets with slight friction. 1 make the bottoms from the high-quality, V$-ir\.-thick birch plywood sold at hobby shops.

After cutting all bottom pieces to size, line the four lower bottoms with velvet. To do this, glue oversize pieces of velvet to the panels with spray adhesive, then trim with a rotary fabric cutter (available at fabric shops).

Glue the bottoms into their rabbets, except for the top tray. I apply a bead of glue in the rabbets' corners—I don't bother spreading the glue. Press the bottom in place and clamp it to the tray. I use two triangular clamping blocks for each tray and apply pressure with C-clamps. The glue will soak into the velvet and form a surprisingly strong bond with the wood.

Under the top tray is a secret compartment. Cut the bottom panel so that it press-fits nice and tight. Then shave V32 in. off the front edge and apply a thin

Sanding faces flush. Tape two sides of the assembled trays together while sanding a third side flush.

Hole alignment Clamp the same assembly jig to your drill press table to position each tray for drilling.

Beveling the fronts. Set your miter gauge to 30* and the blade to 26s from vertical. Clamp a mitered stop block to the fence to help position the tray. Back up the tray with a wood scrap to prevent tearout.

bead of hot-melt glue along this edge. The glue can be compressed for a tight fit and easy removal of the lid with a finger, as shown in the photo on page 49.

Final Assembly

Glue one end of the brass rod into the base with cpoxy or cyanoacrylate glue. Then buff a coat of paste wax onto the rod so the upper trays can pivot freely. Fit the four upper trays onto the rod again. Finally, cut three triangular pads from a sheet of self-stick felt and apply them to the bottom corners of the box. A

Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

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

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