Construction

Tedswoodworking Plans

Ted's Woodworking Plans

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1. Cut the plywood case parts.

Start by cutting out the plywood parts. All the parts listed as being birch plywood can be cut from a single sheet. Fred used good-quality

A serious router and cutter generate enough chips and dust to warrant a no-nonsense dust collection system. A pickup on the fence captures some dust from the table surface, hut the bulk of it is drawn from the router compartment through the 4-inch hos*'.

cabinet-grade birch plywood because it takes paint well. Since they aren't exposed, the two case tops can be cut from less-expensive fir plywood. (Later, you can cut the tablctop core pieces and the drawer bottoms from this plywood.) Cut the drawer runners from '/»-inch fir plywood. Finally, cut the back from a sheet of Winch lauan plywood.

The sides are rabbeted for the case tops (as arc the divider panels) and are dadoed for the middle and bottom panels. The sides arc also rabbeted—Y» inch by 'A inch—for the back panel. Cut the rabbets and dadoes, then glue and nail the drawer runners in place on the sides. (Note that the top-right drawer position has a false front where the on/off switch will be mounted, so it isn't

Pastic Router Mount

ACRYLIC PLASTIC MOUITTINC PLATE

APPLY PLASTIC LAMINATE TOP AND BOTTOM. PLYWOODHWO LAYERS) W»«1**»

NOTCH FOR ROUTER HANDLES IF NECESSARY -

APPLY Vl"*lVl EDGE. 8AN01NC WITU MlTLRED CORNERS

top panel

MOUNT DUPLE* OUTLET M tLtCTRlCAL ©OA.

LEAVE ItW SPACES BETWEEN DRAWER RUNNERS.

NAIL DRAWER RUNNERS TO SIDES I'W.HVf

<M' PLYWOOD BACK PANEL

VTmfOh'llS*

PRILL HOLES FOR ROUTE*

BIT STORAGE.

MOUNT SWTTCW IN ELECTRICAL .BOX IN TOP RIGHT ORAWER FRONT.

PLYWOOO BOTTOH

MIDDLE AND BOTTOM . PANtLS

^PLINTH FITS 1MS1DL CABINET SIDES AT BOTTOM

PLIMTU SIDE, x II Vb"

ROUT W * W RABBET AROUND TMREt SIOE.S OF DOOR BACK.

CABINET ROUTER TABLE

ROUT V»" ROUNDOVER ON FRONT EDGES OF DRAWER FRONTS AND DOORS.

A SHOP TOOL WITH ALL TNt frILLS

necessary to attach runners for a top drawer there.)

The divider panels, too. arc rabbeted for the back. After cutting the rabbets, attach the runners to the rabbeted face.

A port for the dust collector must be cut in the lower left corner of the router compartment back. The opening is roughly oval, about 3Vi inches high and 4'/2 inches long.

The middle panel must be trimmed and rabbeted for the back. First, cut a Vs-inch-wide by '/»-inch-

deep rabbet along the entire back edge. Then measure 6Ya inches in from each side, and mark these two spots. With a piloted flush-trimming bit. trim away the lip forming the rabbet, beginning at the ends of the panel and stopping at the two points just marked. The bit's pilot should ride on the bottom of the rabbet as you trim.

2. Assemble the ease. Begin assembly by gluing and nailing the sides to the bottom and middle panels. The edges of these parts should be flush in the front. Use 6d finish nails. Next, glue and nail the two divider panels to the router compartment back. Glue and nail this unit to the middle panel, then fit the two small case tops into the rabbets cut for them. Again, the case tops' front edges should be flush with the case's front edges. Cut out the '/»-inch plywood back to fit in the rabbets cut for it (leaving the space behind the router compartment open).

3. Make the cabinet's face frame. Make a face frame for the front of the cabinet by cutting K-inch by Winch oak strips to fit. Glue and nail them in place on the front edges of the cabinet parts. Make the bottom strip 1 y« inches wide to cover pan of the plinth. The oak strips arc simply butted together. Chamfer the edges of the oak strips slightly with a chamfer bit.

4. Build and install the plinth.

Cut out the four pieces for die plinth, and rabbet the ends of the front and back ones. .Assemble the plinth with glue and nails, then attach it to the bottom of the cabinet.

5. Make and hang the doors.

The two doors that close in the storage compartment are simple lipped doors. Cut them from the remaining birch plywood. Cut a ^M-inch by H-inch rabbet along the top and bottom and outer edges of each. Don't rabbet the inner edge. Radius all four edge» of the doors with a >ft-inch round-over bit. Hang the doors on self-closing offset hinges. Install the wooden knobs.

6. Build the drawers. The drawers arc simply flat pieces of plywood drilled with holes for bit storage and fitted with a lipped birch-plywood front. To make the drawer bottoms, cut pieces of V*-inch and !A-inch plywood to the length and width specified in the Cutting List.

Before you drill the holes in the drawer bottoms, inventory your collection of bits and small router accessories. Plan how you want to store them, and give yourself space for

I expansion. Drill ^u-inch holes for the Winch-shank bits and lvfc-inch holes for the '/¡-inch-shank bits. Bore the holes all the way through the K-inch plywood. Then glue on a

CUTTING LIST

Piece

Number

Thickness

Width

U*ngth

Material

Top core pieces

2

yv

22W

32'/2"

AC plywood

Hdgc banding

2

y<"

M"

24"

4/4 ock

Edge banding

2

yv

34"

4/4 oak

Sides

2

yv

1Q7/«"

?Q'A"

Birch plywood

Middle panel

1

y<"

19%"

27/4"

Birch plywood

Bottom panel

1

yv

19 y*"

27/4"

Birch plywood

Divider panels

2

Yi"

19 Vi"

15"

Birch plywood

Router compare-

ment back

1

13"

15"

Birch plywood

Top panels

2

w

6Y*"

19y8M

AC pi;,-wood

Drawer runners

2

W

1%"

i9y«"

AC plywood

Drawer runners

4

tt"

2W

I9yn"

AC plywood

Drawer ninncrs

8

V*"

2W

i9y«"

AC plywood

Back panel

1

/«"

27w

29%"

Lauan plywood

Face frame rail

i

yv

yv

26Y2"

4/4 oak

Face frame

bottom rail

1

yv

l yv

26'/2"

4/4 oak

Face frame rails

2

yv

yv

7y2"

4/4 oak

Face frame stiles

2

Y<"

yv

29'/«"

4/4 oak

Face frame stiles

2

Y<"

y

14/4"

4/4 oak

Plinth front

and back

2

VA"

26'/i"

Fir

Plinth sides

2

l

w

19 y*"

Fir

Doors

2

vr

UY*"

13 y«"

Birch plywood

Drawer fronts

4

y."

W

3Yi"

Birch plywood

Drawer fronts

4

y."

m"

4"

Birch plywood

Drawer bottoms

7

y."

>yv

20"

AC plywood

Drawer bottoms

7

W

5Yt"

20"

2 pes. 24" x 34" plastic laminate 1 pc. X 7Yi% X lOH" clear acrylic 1 pc. Vi" x 4" x 5" clear acrylic I pc. 4" sheet metal T-fitting 6d finish nails, as needed 4 pes. 2" drywa.I screws

4 pes. y«" self-closing offset hinges 9 pes. 1" dia. wooden knobs, with screws contact cement yellow glue

2 steel receptacle boxes

I pc. 2(kimp duplex receptacle 1 pc. 20-amp single-pole switch 1 steel receptacle plate 1 switch plate

5' electric cable, 12/2 with ground I pc. 3-prong plug

10'-20' electric cord. 12/2 with ground

Router Techniques Woodworking
FRONT DRAWER DETAIL

ROUTER COMPARTMENT BACK X

SHOP-VAC-SIZtO U05E FROM TABLETOP-MOUNTED PICKUP

I SCREW DRIVEN } THROUGH FITTING • "7 (FROM INSIDE) f—f INTO oivioeR

CLOSING THE OPENING HAS THE EFFECT ,—. OF INCREASING s4CS THE SUCTION. /;. \

ADJUSTABLE [NOSE CLAMP

ACRYLIC GATE

SHEET METAL' T-FIT TING

4' FLEXIBLE UOSE TO OUÎT COLLECTOR (NOT A SHOP VACUUM)

SIDE VIEW

OUST COLLECTOR DETAIL

DRAWER FRONTS

bottom panel divider panel

ROUTER COMPARTMENT BACK

middle panel

BIRCH PLYWOOD CUTTING D1ACRAJA

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Wood Working for Amateur Craftsman

Wood Working for Amateur Craftsman

THIS book is one of the series of Handbooks on industrial subjects being published by the Popular Mechanics Company. Like Popular Mechanics Magazine, and like the other books in this series, it is written so you can understand it. The purpose of Popular Mechanics Handbooks is to supply a growing demand for high-class, up-to-date and accurate text-books, suitable for home study as well as for class use, on all mechanical subjects. The textand illustrations, in each instance, have been prepared expressly for this series by well known experts, and revised by the editor of Popular Mechanics.

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