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American: Woodworker MARCH 2007

^^^ updated construction yet traditional looks

Build the Plywood Case

1. Cut the plywood case parts (A1 through A7, Fig A, Plywood Cutting Diagram, page 50; Cutting List, page 52).

2. Assemble the bottom, lower partition, middle divider, drawer partitions and subtop with glue, screws and biscuits.

3. Attach the sides (A6) to the plywood case (A1 through A5). Use a 1-in. spacer board at the front corners to create a notch for the legs (Bl) to fit into (Photo 1). A precise 1-in. setback ensures that the face frame, which later attaches to the plywood case, lines up evenly with the front face of the legs.

Add the Leg Panels

4. Make the legs (Bl). Cut the tapered foot (Fig. A) on your bandsaw and use a belt sander to smooth it. Cut a stopped groove for the 1/4-in. center panel (B2) using a slot cutter on your router table (see Sources, page 52).

5. Cut the stopped rabbet in the back of the rear legs for the back panel (A7) (Fig. A).

6. Make the top and bottom panel rails (B3, B4) and rout grooves in these parts for the center panel.

7. Assemble the leg panels (Photo 2). Use biscuits and glue to join the rails to the legs. When the glue is dry, clamp the leg panels to the plywood case.

8. Cut filler boards (B5, B6) and test their fit (Photo 3). You'll need to adjust the thickness of these fillers if the plywood you used for the plywood case sides (A6) is not exactly 3/4 in. thick (3/4-in. plywood commonly runs undersize).

9. Unclamp the leg panels and glue the filler boards to the inside surface of the rails. When the glue is dry, attach the leg panels to the plywood case with screws only (Photo 4). Note: Do not use glue at this time. Notice that the screws run through the plywood sides in the drawer opening and below the case's bottom. These screws are hidden when the sideboard is complete.

Make the Face Frame

10. Cut out the face-frame parts (B7 through Bll). Test-fit the face-frame rails between the front legs on the cabinet to make sure they are the correct length.

11. Assemble the face frame with dowels (Photo 5).

12. Attach the face frame to the plywood case (Photo 6). Use biscuits to align the face frame to the plywood case. Note: At this time, do not put glue on the end of the rails where they meet the legs.

13. After the face frame is attached to the case and the glue has dried, unscrew and remove the leg panels.

14. Cut biscuit slots in the ends of the rails. The middle and top rails are too narrow for a full biscuit. Position your biscuit joiner on the ends of these rails so the slot breaks out at the top of the rail, but not on the bottom. This will produce a slot for a half-length biscuit. The bottom rail is too narrow for two full biscuits. Position the biscuit slots in the ends of this rail close together so they don't break out at either the top or bottom. Cut the biscuits for these slots to about three-quarters of their length. Cut corresponding biscuit slots in the front legs.

15. Apply glue to the filler boards' inside surfaces, the ends of the face-frame rails and the biscuit slots on the legs. Reattach the leg panels to the plywood case (Photo 7).

Complete the Case

16. Glue up the top (B12) and attach it to the plywood case with screws. The holes in the plywood subtop (A5) should be drilled oversize to allow seasonal movement of the top because it's solid wood.

17. Attach the back panel (A7).

18. Cut the shelves (A8) and glue on their edging (A9).

19. Drill for shelf pins (see Sources, page 52).

ยง Add the Drawers

20. Make drawer boxes with lipped fronts (Fig. A, Detail 1). I used a half-blind dovetail jig with a 1/2-in.-

o dia. 14-degree dovetail bit. My jig produces dovetails g on 7/8-in. centers, so I ended up with good-looking half pins on both the top and bottom of the drawer sides (see photo, page 52, bottom). (For information, see "Making Lipped Drawers with a Dovetail Jig," AW #84, December 2000, page 91, or www.american

21. Groove the drawer sides, back and front for the drawer bottoms (CI through C4). Round the front edges using a 1/4-in. round-over bit in your router table. Then assemble the drawers.

1 Begin building the sideboard by constructing a simple plywood case using glue, screws and biscuits. When you attach the sides, use a spacer to ensure a precise setback from the case's front.The legs will fit into the notch that this setback creates.

2 Glue the leg panels.The center piece fits into a groove in the top and bottom rails and legs, and the rails attach to the legs with biscuits.

Clamp the leg panel to the plywood case. Test-fit the thickness of filler boards in the spaces between the rails and the plywood case side. When the fillers are planed to the correct thickness, remove the leg panel and glue the fillers to its top and bottom rails.

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