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Step 3: Drill end holes through drawer face. Note that holes are smaller than width of slot.

Step 4: Jigsaw cut between end holes (to within 'At in.of trace line).

Step 5: Reclamp template in place to trace line of slot. Use a pattern-following bit to clean drill hole and cut lines to template pattern. Then shape the slot as shown below.

Pattern bit

Pattern bit

Template CROSS SECTION

Template CROSS SECTION

%8nn. cove bit on bottom edge of slot trace lines and use the pattern following bit on the router to clean up the cut. To shape the pull, first round over the outside edge of the slot with the router (using a '/«-in. roundover bit), then form the undercut with a J/s-in. cove bit. I land-sand the cut edges with Fine sandpaper.

Ogo Dour Cove

Using a story stick, mark the position of the drawer hardware along the case blocking. Photo by Craig Wester.

After cutting all the joints, fit a slotting bit into the table-mounted router and cut the grooves for the '/»-in. plywood bottom panels. Cut the bottom panels to size, checking to be sure they are square, and then dry-assemble each drawer. If the joints arc tight and the box sits square and flat, proceed to glue up the boxes. You can use nails to hold the joints together while the glue dries, or case clamps if you find nail holes offensive.

Cut the drawer faces out of a length of solid stock. You can either cut each face from the board individually, or, to reduce waste, you can edge-glue a panel the width of all the drawer faces together

(plus saw kerfs) and then rip out the individual faces. The finger pulls can be made quickly and precisely with the aid of a router template, as explained in the sidebar on p. 121.

Final assembly and adjustments

Screw the top frame to the case from above, attach the figure-eight desk-top fasteners, and then turn the case over on top of the table. Screw through the fasteners into the table. Turn the case back over, this time on top of the base frame. Screw through the floor of the case into the frame.

Now install the drawer hardware to the blocking along the case sides and to the sides of the drawers, using a layout stick along the blocks to ensure accuracy in locating the attachment holes. You can use the same layout stick to mark the position of the hardware on the drawer sides. Slide the drawers into the case, adjusting the position of the hardware if necessary to allow the drawers to run smoothly and sit level in the opening.

Now you can install the faces (see the drawing at right). First, hammer a pair of brads partway into the back of the faces where the attachment screws will be fitted, and then clip off the heads to form a point. Next, starting at the bottom, press the bottom drawer face against its box after carefully aligning the edges of the face with the bottom and sides of the case. Drill shank holes for the attachment screws at the marks left by the brads. Then remove the brads from the back of the face and drill pilot holes for these same screws. Install the face to the box. Repeat the process with the next drawer face, this time aligning it to the face below. Use even-sized shims (laminate sample chips work well) to hold an even gap with the wer face below.

Finally, attach the casters to the base frame by drilling pilot holes for, and ailing, machine screws. (Tapered ! screws have a tendency to work in this high-stress situation.) ch a pair of loose leaf hinges to the ¡parts of the extension-wing supports, install the 3/4 -in. spacer to the case side I then install the swing-out supports by engaging the hinges. Finally, attach ! the wings to the table with a pair of butt -:-ges (or a length of piano hinge).

Step 3: Drill shank holes in drawer box at brad marks and pilot holes (for threads) at location of removed brads in drav/er face.

Step 4: Install bottom drawer face with screv/s, then hold next face (with clipped brads) against next drawer box. Use shims to maintain even gap. Repeat steps.

Drav/er boxes

Bottom drawer face

Step 1: Hammer brads into back of face and clip off heads.

Step 2: Align face to edges of case, then press face against drawer box to imprint brads.

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Woodworking Tools and Installation Tips

Woodworking Tools and Installation Tips

There are a lot of things that either needs to be repaired, or put together when youre a homeowner. If youre a new homeowner, and have just gotten out of apartment style living, you might want to take this list with you to the hardware store. From remolding jobs to putting together furniture you can use these 5 power tools to get your stuff together. Dont forget too that youll need a few extra tools for other jobs around the house.

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