Router Joinery

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As I mentioned earlier, I used dadoes to join the case sides and dividers to the top and bottom. Since this joint will be "front and center," it's very important to cut perfectly smooth, flat, and chipout-free dadoes. To do this, 1 used my router table and a W straight bit, as in the photo at right.

ROUTING THE DADOES. The key to making the drawer compartments of the case identical in size is cutting evenly spaced and matched dadoes in both the top and bottom.

All it takes is a couple simple steps, like you see in Fig. 1 at right. Start by routing the dadoes for the dividers. To do this position the fence so it's 7V4" away from the bit. Then set the router bit to cut '/j" deep.

To prevent chipout as you complete the cut, use a backer board to push the workpiece over the bit, like you see at right. After completing the first cut, simply rotate the work-piece end for end and rout the dado for the second divider. Then, repeat the process on the bottom of the case.

The next step is to rout the dadoes at the ends. What's important here is to reset the fence so that after routing the two dadoes, the spacing between aLl of them is identical. In my case, I reset the fence lA" from the bit.

ROUTING STOPPED RABBETS. You'll also need to make a couple of rabbets to hold the back of the case. If you look closely, you'll notice the rabbets are "stopped." That's so they aren't visible on the sides of the case. To make these cuts, you'll want to switch to a V4" straight bit.

To match the depth of cut, you can use one of the dadoes you just routed as a setup gauge, as shown in Fig. 2 at right. I found it easiest to align the workpiece over the bit and then "drop" it down to begin the cut (Fig. 3). Just be sure to stop the cut when you reach the dado that's at the end of the workpiece.

Finally, rout or sand a roundover to ease the edges (Figs. 4 and 5).

• Tlje'router, taty' jnc! a 'h* straight bit is a1' iU'lakes tr ¿dke smooth, flat-bottomed' dacks»' ft simple backer Ijeard prevents .c^jtft atjHe end of the cut.

make a second pass. Then you can reset the fence to space the dadoes evenly, as shown in detail 'a,' and rout the dadoes for the sides.

The first step in cutting the dadoes is to set the fence to cut the dadoes for the dividers. After you rout one dado, flip the workpiece end for end and make a second pass. Then you can reset the fence to space the dadoes evenly, as shown in detail 'a,' and rout the dadoes for the sides.

dado depth

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ft

P*

1,

V

II"

Reset the fence and rout the rabbet along the back edge of the top and bottom. Stop the cut

After installing a V bit in the router, you can use one of the dadoes you just routed as a setup

Reset the fence and rout the rabbet along the back edge of the top and bottom. Stop the cut gauge for setting the depth of cut for the rabbet, when you reach the end dado (detail 'a')

NOTE: Round over ends of top and bottom and fronts of edges sides and dividers

After routing the dadoes and rabbets, switch to a Vg" roundover bit to soften the ends of the case top, bottom, sides, and dividers.

/ \

a.

Sand

SIDE

radius

VIEW

V

J

It's almost impossible to rout a roundover on the small ends of each piece. So it's best to switch to fine sandpaper and a sanding block.

Center bin pulls in opening onjlrawer front

NOTE: Sand or rout an '/g" roundover on edges of cutout

DRAWER SIDE F)

Center bin pulls in opening onjlrawer front

NOTE: Sand or rout an '/g" roundover on edges of cutout

DRAWER SIDE F)

Joinery Details Key Board Drawer

VIEW I

DRAWER BACK

Brass bin pull two-way Drawers

TOP VIEW

DRAWER FRONT (T>-

DRAWER SIDE

VIEW I

DRAWER BACK

-hole for stem bumper

DRAWER . SIDE

Brass bin pull two-way Drawers

SIDE SECTION VIEW

DRAWER

DRAWER BOTTOM

ÇA" hardboard)

DRAWER

DRAWER BOTTOM

ÇA" hardboard)

Drawer back sits on bottom

Stem bumper

Drawer back sits on bottom

With the case complete, you're ready to turn your attention to the drawers. The challenge is to build the drawers to match the openings in the case so they fit well — whether the case is set horizontally or vertically.

DRAWER DETAILS. The drawers are built to have a small VW' clearance side to side and top to bottom. And if you take a quick look at the drawing above, you can see how the back of the drawer is recessed just a bit. This way you can pull out the drawer and easily access the DVDs without the drawer falling out of the case. Finally, to "dress up" the fronts of the drawers, I added a miniature hardwood face frame.

FRONTS AND SIDES. Since the front of the drawer determines the overall fit, I started by cutting the drawer fronts to fit the opening, allowing enough for the Vié" clearance.

While I was at it, I cut the side pieces to the same width and trimmed them to final length. Then, to make it easy to reach a DVD inside the drawer, I made a cutout along the

DRAWER CUTOUT PATTERN

-—V/a—

«■- 6 -•»

-3 -

radius ,

DRAWER FRONT

Enlarge 200% for full size template

top edge of each side, as in the drawing above and pattern below.

ROUTING A LOCKING RABBET JOINT. To join the fronts and sides, I used a locking rabbet joint, as shown in detail 'a.' The opposite page covers everything you need to know.

ADDING THE BACK & BOTTOM. Once you have the locking rabbet joints cut, you're ready to add the back and bottom. The back fits into dadoes cut in each side piece (detail 'b') and the bottom fits into grooves cut in the front and sides (detail 'c'). After cutting the drawer bottom and back to size, you can glue up the drawer.

FINISH IT OFF. To give each drawer a finished look, I created a face frame by gluing on thin strips of hardwood on the drawer fronts (see drawing). Finally, I added some plastic bumpers and a brass bin pull.

Now all that's left to do is round up your DVD collection, organize them the way you want, and then slip them in place.

How To:

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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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