Making the case
Cut the sides, floor, and back panel of the case from 3/<-in. hardwood plywood, then cut the full-length rabbet to receive the back panel in both side pieces. Make the slots for the biscuits where the sides join the floor by folding—and clamping in place—the floor panel over each of the >ide panels in turn. This technique does two things: It allows the floor to act as a stop for the base of the joiner when slotting into the face of the sides, and it places the floor in a good position to be end-slotted at the same layout marks. See the drawing below for details.
Drv-fit the case parts together. When you're satisfied with the fit, proceed with wet assembly. If you wish, you can save the trouble of clamping up the assembly by screwing the components together. (For appearance's sake, you can countersink the screws and insert wood plugs to hide the heads.) Glue and screw the assembled face frame to the front edge of the case. To improve the appearance of the joint between the frame and case, I bevel the edges of the joint. I use a dual-purpose flush and V-groove router bit designed especially for this application. It trims the face frame flush to the case side while at the
A flush and V-groove router bit trims the face frame to the case side. Photo by Craig Wester.
Slotting Case-Panel Butt Joints
Step 1: Clamp floor (upside down) to left side. Run machine in at centerlines of slots.
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