Tray

With the lid attached, the last step is to build a tray that fits inside the case and slides back and forth on the tray supports.

First, the tray front/back (J) and tray ends (K) are cut to finished size. Then to join all the pieces of the tray, I cut the dovetails by hand — just like the case, see Fig. 11 and the drawing at right.

Next, I cut a W-wide groove 3/&" deep in each piece for the tray bottom, see Fig. 12. The bottom is another solid wood panel. This time, it's glued upfront V£"-thickstock, see drawing at right.

When the tray bottom (L) has been glued up, I cut it to finished size. The panel should fit inside the tray (including the grooves) minus Of course, a ^"-thick panel won't fit into a Wgroove. But I cut a rabbet along the bottom edge ofthe tray bottom to create a V4" tongue, see Fig. 12.

Next, I wanted to add some "handles" to the ends of the tray. These handles are simply slots drilled and cut in the end pieces, see Fig. 13. To do this, first drill l"-dia. holes to establish the length of the handle slot. Then clean out the waste with a sabre saw. Now sand them and rout a small chamfer on both the inside and outside edges. Then the tray can be glued together.

With the tray assembled, there are two steps left. First you want to chamfer the inside and outside edges so there are no sharp corners, see drawing above right. And finally, don't forget to plug the noles in the endpieces thatwere created by the grooves for the tray bottom, see Fig. 14. □

TRAY BACKxi

THAI END K)

TRAY BACKxi

THAI END K)

TRAY FRONT

Va" chamfer on inside and outside edges of tray £

TRAY FRONT

2v2"

TRAY FRONT/BACK

TRAY BOTTOM

NOTE: Cut tray bottom Vs"smaller than groove opening chamfer on inside and outside edges chamfer on inside and outside edges

NOTE: Cut tray bottom Vs"smaller than groove opening

Plug grooves in ends and trim flush

MATERIALS

A

Front/Back (2)

3A x 18V5 - 36

G Trim Front/Back (4)

Vi X 3/4 - 40 rgh.

B

Ends (2)

3/4x181/5-16

H Trim Ends (4)

Vi x 3/4 - 20 rgh.

C

Bottom (1)

3/4x15Vfe-35Ms

I Lid (1)

11/16X18-38

D

Tray Supports (2)

3/4 X 3/8 - ;

J Tray Front/Back (2)

3/4x31/2-24

E

Base Front/Back (2)

1 Vie x 3 - 40 rgh.

K Tray Ends (2)

3/4 x3Vi- 143/8

F

Base Ends (2)

1 Vi6x3 -20 rgh.

L Tray Bottom (1)

Vix13Vi-23Vfe

%

" x 96" (Four boards

3.3 bd. ft. each)

1

A

I

A

*

-G-

L

L L

V 96" (Two boards @ 6.6 bd. ft. ea

ch)

1

-mm,

E

v/Mmm,

(1 pair) 3" No-mortise Hinges

(1) 15" Brass Chain

Plug grooves in ends and trim flush

(1 pair) 3" No-mortise Hinges

(1) 15" Brass Chain

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