After drilling a shallow hole in the clotfing-door stile for the liullet catch, file a ramp to make the catch work smoothly.
m the bit and just touching it. Clamp a scrap of wood on the other side of the cutter to stop the mortise exactly I in. from the shoulder of the stub tenon. Adjust the height of the router bit until it is barely touching the stub tenon.
Now you can rout the mortises. Feed each post into the bit, sliding the glass kerf on the guide strip. Remember, the door stiles are in. shorter than the shouldcr-to-shouldcr dimension of the posts, so make the mortises lAi in. shorter and rip Kz in. oft" the width of the door rails.
Now you can preassemble the fixed posts between the top and bottom of the case. Drill pilot holes in the ends of the posts for the assembly screws, using the clearance holes in the top and bottom as guides.
To construct the door, first drill and counterbore the stiles for the rail-assembly screws, as shown in Fig. I. Clamp the rails in position between the stiles, and drill pilot holes in the rails with a "c-in. bit in a hand-held drill, using the counterbored holes in the stiles as guides.
The hinge stile of the d(x)r pivots on metal pins set into holes in the top and bottom of the cabinet. (See Fig. 1.) 1 made my pins from Mn. long segments of the same rail stock I used for the shelf rests. Drill Vin. deep holes in the ends of the hinge stile and in the top and bottom for the hinge pins.
Glue the rails to the top and bottom of the cabinet with a thin film of yellow glue, clamping them lightly with spring clamps. (See photo, previous page.) Position them by temporarily installing the adjacent posts as you go.
Allow the glue to dry, clean off any excess, and apply the finish of your choice to all parts of the cabinet. I wiped on a few coats of an oil finish, but suit yourself. Try not to get any oil on the bracket dovetails or sockets.
Now you're ready to put the cabinet together with the glass and mirror in place. You may wish you had three liands during this process, but I'm living proof that it's possible for one person to work alone.
First, glue the brackets into the dovetail sockets in the bottom. Next, screw the door together with the glass in place so it's ready when you assemble die rest of the cabinet. Square up the door if ncccssarv with thin shims between the glass and the rails.
inserting the top tenons of the posts into the mortises in the lop of the cabinet and anchoring them with the trim-head screws. Carefully slide the glass and mirror into the grooves in the posts. Stand the door in place and secure it to the adjacent posts with masking tape. Then carefullv maneuver the bottom
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