Stacking DVD Cases

If you decide to make more than one of the DVD storage cases on page 16, you'll probably want to be able to stack the cases on top of each other. To connect the cases but still allow them to be taken apart later for a different configuration, I installed machine screws and matching threaded inserts (see photo at right).

DRILLING THE HOLES. If you take a look at details 'a' and 'b' below, you'll see that countersunk holes are drilled in the bottom of the upper case for the machine screws. Then laiger holes are drilled in the top of the case below for the inserts.

The trick is to make sure that the insert holes in the lower case line up perfectly with the screw holes in the upper case. To do this, I set up a fence and a stop block on my drill press, and used this setup to drill all the holes, see drawing below. (You'll have to flip the work-piece over to drill all the holes.)

Once all the holes are drilled, you can install the inserts. The inserts I used are threaded on die inside only — to match the threads of the machine screws. The outside of each insert is covered with little barbs. As the insert is driven into its hole, the barbs dig into the wood and prevent the insert from being pulled out.

INSTALLING THE INSERTS. My first instinct was to hammer the inserts into the holes. But I quickly realized that this might damage the workpiece (or the insert). So instead, I decided to press each insert into its hole.

The answer was a simple C-clamp. I first threaded a machine screw into each insert to act as a driving ram. Then I used the C-clamp to gently press the inserts into the holes, as you see in the drawing in the upper left. A backer board placed behind the workpiece will prevent the head of the C-clamp from marring the wood.

Installing Inserts. The inserts are pressed into the holes using a C<lamp and a machine screw. A backer board prevents the clamp head from marring the workpiece.

Barbs on the outside of these inserts prevent them from being pulled out of their holes once they're installed.

a. Countersink

FRONT forW

SECTION .—machine

VIEW f screw

Sfa'-dia. through hole

through hole

NOTE: See page 18 for placement of inserts

Stop block a. Countersink

FRONT forW

SECTION .—machine

VIEW f screw

Sfa'-dia. through hole

through hole

NOTE: See page 18 for placement of inserts

Stop block

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Wood Working 101

Wood Working 101

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