HowTo Bottom Edge Profile

NOTE: Make two passes on router table to complete edge profile

Make shallow

Complete with



#8x IV4" F h woodscrew

Drop-leaf hinge with screws

#SxVA° Fh woodscrew

Case bottom

NOTE: Glue magnet in place with epoxy

W-dia. button plug roundover1


Bottom screw plugs trimmed flush

NOTE: Filler strips are cut to fit and glued in place

NOTE: Top and door are made from fy"-thickpine

MAKE THI "DRAWERS." Once the mortises were cut, I started work on the false drawers. The idea here is to cut equally spaced kerfs in the door to give the appearance that the storage center holds four drawers (see detail V above and tire right drawing in the box below).

Before assembling the case, there are a couple more things left to do. First, drill holes for the knobs (drawing on opposite page). And second, install a magnetic catch (detail 'a' on opposite page). Once these things are completed, you can assemble the case.

SHELF TOP. The next step in the construction is to add the top to die case. I routed a V roundover with

With the case parts done, it's time to add the final touches. There's a fair amount of work to be done to the door, like completing tire rule joint, routing the hinge mortises, and making the "drawers." So that's a good place to start.

DROP-FRONT DOOR. After cutting the door to size, the first step is to rout a cove on the bottom edge of the door (see left drawing below). The cove will mate with the roundover routed on the front edge of the case bottom to create the rule joint.

HINGE MORTISES. The next tiling to do is rout the mortises for the hinges. To make sure the mortises in the door and bottom were aligned, I laid the door in front of the bottom and marked where they should go (see main drawing and detail 'a' above). Shop Notebook on page 28 shows how to mark the locations of the hinges and install them.

Aux. fence



The Cove. The profile routed on the bottom of the door should mate with the edge of case bottom.

Cutting Drawers, Three evenly spaced kerfs cut into the front of the door creates the illusion that the storage center contains four small drawers.

Distressing the finish gives the storage center a comfortable, time-worn appearance.

W-dia. magnet washer a shoulder along the front edge and the sides (detail 'a'). Then, you can simply glue the top to the case.

FILLER STRIPS. There's one final detail before moving on to the finish. Some of the grooves you cut earlier are visible on the inside of the case. Although it's not a big deal, £ decided to glue in filler strips to give it a more finished look. Now, you're ready to move on to the finishing stage.

-IVb'-dia. wood knob


To give the shelf an antique look, I decided to "distress" it. What that means is taking a couple of tools or a ring full of keys and drop them randomly on the storage center. But don't get carried away — you want it to look old, but not beat up. I also softened some of the edges to add to tlie worn appearance (see photo on the opposite page).


Then, I applied a walnut stain to the entire project. When that dries, paint right over the stain.

Once the paint dries, lightly sand in different areas to dull it or to allow the stain to peek through. This really adds to die aged look.

But there are other looks for this shelf as well, as you can see Designer's Notebook below. £3

#6 x V Fh woodscrew

Vs" x V/Y knob bolt


W-dia. washer

Divider magnet

-Cove-bead profile on edge of top

Metal door knobs

While working on this project, 1 couldn't help but think of all the different design options that could easily change the look of this project. A couple of ideas are shown in the drawings here.

For a more traditional look, you can change the edge profile of the top, add wood pegs, and cut an ogee profile in the aides. The detail drawings can help you with that.

Or, go with the straight lines shown in the drawing below for a clean, contemporary look.


Wood pegs

Side has^ ogee profile

Va" radius

Top has flat edge with softened corners


Side has simple rnitered profile


3Vt" radius

Single metal hooks


Was this article helpful?

0 0
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.

Get My Free Ebook

Post a comment