Side View

Ebony latch


Note: Latch is tapered so it clears front edge of mortise when lid is lifted.

Ball-point pen spring

Drop panel

Vs-in. lock pin through from inside


All-wood slides allow the drawers to extend fully for full access. Photo by Charley Robinson.

Start by making a full-size drawing of the side of the toolbox and the drawers. Also draw front views to determine the layout of the sliding dovetails and the grooves. Draw in the parts of the extension system, including the runner (which is fixed to the case side), the slider (which runs between the runner and the drawer box) and the side of the drawer box. If you need more clarification, also draw the box fully extended out of the case.

Measure the size of the parts on the rendering and then cut them out of dear, stsbir hardwfjod stock. (Teak would be a good choice because of its self-lubricating qualities and its inherent stability.) To keep things simple, make the slider the same thickness as the drawer side. Note that the drawer face will overlap the end of the runner, hiding it from view. Also note in the cross section that the slider is slightly narrower than the drawer side. This difference in height prevents the slider from binding against a cross rail or a tightly fitted neighboring drawer as it moves out of the case.

Set up a dovetail bit on a table-mounted router to cut the dovetailed edges of the runners and sliders. Use the same bit—set to the same height—to produce the angled sides of the grooves. When cutting these grooves in the sliders and drawer-box sides, make successive cuts toward either side, starting at the piece's centerline. This way the grooves will be exactly centered. Now size the sliding dovetail to fit. Though you want the fit to be tight to reduce wiggling, you need it loose enough for a smooth sliding action. Make trial cuts

All-wood slides allow the drawers to extend fully for full access. Photo by Charley Robinson.

in scrap stock first to test the action.

Cut the slots for the stop pins in the sliders. A cutting jig to guide a plunge router fitted with a straight bit will help make this task go quickly and with the necessary precision. Note in the slot/pin layout drawing below that the slots run from 1 in. in from the end of the slider to 1 in. on the far side of the centerline. These distances must be equal for the slider to extend exactly half its length out of the case. (The drawer will also pull out half its

All-Wood Extension-Slide System

length along the slider (and thus fully out of the case).

After assembling the drawers and installing the runners in the case, the next step is setting the stop pins. Karen Robertson made her pins by modifying a brass wood screw: After running in the screw to establish the threads, she backed it out and filed the head flush to the shank. To find the location of the pin on the case side, install the slider on the runner. Push it all the way in and then make a mark at the front end of the upper slot. In a similar fashion, mark the pin location on the drawer side with the slider installed tight against the face of the drawer. This time make the mark at the rear end of the lower slot.

Prcdrill for the screws at the marks.

Install the drawers by-sliding in the sliders on their runners. Screw the stop pin in through the slots into the case sides. Now fully extend the sliders from the case and slide in the drawer box, and screw the stop pin into the side of the drawer box. Rub wax from a candle stub liberally on the sliding surfaces. Test the action. If they bind, the runners may not have been installed parallel. You can remedy the problem by using a scraper blade along the edges of the sliding dovetails where binding is evident (you can usually see a burnished surface where rubbing occurs).

Was this article helpful?

0 0
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.

Get My Free Ebook

Post a comment