There are still a few things left to add before the case is complete — a set of plywood dividers and the face frame. Then, you can get to work on the case top.
BOTTOM AND DIVIDER. Before jumping in on the face frame and closing up the case, you'll need to wrap up a few things on the inside. To do that, cut three plywood panels to size. Two of the panels are identical and will be used as a divider and case bottom, as shown in the drawing above.
SHELF. The third panel you cut will become the adjustable shelf in the enclosed lower section of the case. This panel is slightly smaller than the other two so it can be installed easily. And it has a ^"-thick hardwood edging strip glued to the front to conceal the plywood edge, as in detail 'a.' (You can set this aside for now.)
The divider and bottom panels can then be glued into the dadoes that were routed in the case sides earlier. A nice side benefit of these pieces is that they help square up the case.
sizing the stiles and rails, I got to work on the mortises.
MORTISES. To create the mortises in the stiles, 1 used the technique of drilling out the bulk of the mortise over at the drill press. Then I went back to the bench and cleaned up the "roughed-out" mortises with a chisel. You can leam the ins and outs of this technique on page 12.
TENONS. After finishing up work on the mortises, it's time to cut the matching tenons, as shown in details 'b' and 'c.' To keep things simple and efficient, I cut them on the table saw with a dado blade.
All that's left to do before gluing up the face frame is to complete a couple of details. First, you can cut a curve in the w bottom rail to match the curves on the sides and back.
TAPERS, THEN GLUEUP. Second, the bottoms of the stiles can be tapered just like those on the sides and back. Now, glue up the face frame taking care to keep it square as the glue dries.
After removing the clamps, the last thing to do on the face frame is to cut a rabbet on the back face of each stile. This rabbet will capture the side frames and make assembly easier.
CASE ASSEMBLY. Gluing the face frame in place is pretty straightforward. And like die earlier assembly, it's a good idea to concentrate on creating a tight joint line between the side stiles and the rabbets cut in the face frame.
All that's left to do on the case is to rout a stopped chamfer on the front corners. And you can iearn how to get the best results in the box at right.
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