Cutting Diagram

x 5"- 96" Cherry (4 boards @ 3.33 Bd. Ft. ea.)

A

A

3/a" x 5"- 96" Cherry (3.33 Bd. Ft. ea.)

B B B

B

B B

B '///8 ////.

x 5V2"- 96" Cherry (3.66 Bd. Ft.)

E

* \ *

£

3A" x 5V2'- 96" Maple ( 2 boards @ 3.66 Bd. Ft. ea.)

C

G G /////

V x 9/2°- 96" Maple (3.66 Bd. Ft.)

F

F

F

F 1

/ / / / / s / / /

The next step is to cut W-deep rabbets on the ends of the sides to hold the top and bottom panels, see Fig. lb.

The center divider is set in a dado cut across the top and bottom panels, so I cut these dadoes next, see Fig. la. And to hold the V4n-thick plywood back, I cuta VS"-wide rabbet on the top, bottom, and side panels, see Fig. lc.

When the rabbet for the back is cut, dry assemble the case and cut the divider to fit between the grooves in the top and bottom, see Fig. 1. Then rip it to width so it's flush with the front of the case and stops at the shoulder of the rabbet for the case back.

At this point, the inner case can be glued and screwed together, see Fig. 2. The center divider is simply glued in place because I didn't want screws visible from the top of the inner case. Then when the glue's dry, you can cut a back (D) to fit the rabbets and screw it in place, see Fig. 1.

#8x V/2" Fh woodscrew

a, cross section

#8 x V/2" Fh woodscrew

Rabbet for case back

a, cross section

#8 x V/2" Fh woodscrew

#8x V/2" Fh woodscrew

Rabbet for case back

TOP/BOTTOM

DRAWER BACK

DRAWER SIDE

Now that the inner case is complete, all that's left is to add the drawers.

DRAWERS. To determine the height of the drawers, measure the opening and subtract 3/i6" for the gaps at the top and bottom and between the drawers. Then divide this number by two. (Mine were 5V41' tall.)

With the pieces cut and the dovetails routed, next cut the openings for the handles on the drawer fronts, see Figs. 3 and 3c.

Shop Tip: After the handle was cut out of one drawer front, I used it as a template for marking the other fronts.

With the handles cut, the drawers can be assembled. Then rout a stopped groove along the sides of each drawer, see Figs. 3a and b. This groove is centered on the side pieces and is part of the drawer runner system, see page 26. (For some tips on cutting this stopped groove, see page 29.)

runners. Now the four drawers can be installed in the case. This means cutting a drawer runner (I) that attaches to the inner case and fits into the grooves on the sides of the drawer, see Fig. 4.

Installing runners in the case can be tricky. They have to be parallel to each other and level, and they must be located 3/4M from the front of the case, see Fig. 5. To make this easier, I set the runners on spacers. Then I simply have to position them front to back. And since the runners are screwed to solid panels that need to expand and contract, I used slotted holes, see Fig. 5 and page 26.

DRAWER BOTTOM

DRAWER SIDE

Center drawer bottom-—— groove on first full dovetail pin

Drawer runner groove

DRAWER FRONT

DRAWER FRONT

DRAWER FRONT

plywood bottom .

Center drawer runner groove

Center cutout on drawer front view filler strips. Once the drawers slide smoothly, the inner case is almost ready to be set in the wardrobe. But just like the shelf in the wardrobe, there are gaps between the inner case and the side panels. These require some filler strips.

The two side filler strips (J) for the sides are identical to the ones used in the wardrobe, see Fig. 6. But there's one more filler strip needed. It's a back filler strip (K), and it will be thinner than the sides, see

Fig. 7. (Mine was VS".) There's another thing different about the back filler strip. Instead of gluing it to the back of the wardrobe, I screwed it to the inner case. Just make sure it ends up flush with the tops of the filler strips on the sides.

With the filler strips in place, the inner case can be finished just like the wardrobe. When the finish is dry, simply slide the case into the wardrobe, see Fig. 7. It's heavy enough that you won't need to secure it. □

DRAWER RUNNER

cross section

%"-dia. counter-bore, 1A" deep cross section

(TOP VIEW)

W-dia. shank hole

\ shank \ hole Vs"-dia. counterbore

Center

DRAWER RUNNER

NOTE: Runners must: short of back

WasherCENTER DIVIDER (c

NOTE: Round over front to match groove

- Filler strips should align at top

SIDE FILLER STRIP

BACK FILLER STRIP

SIDE FILLER STRIP

NOTE:

Attach back strip with #8 x W'Fh woodscrews

Clamp side filler strip with spring boards

BACK FILLER STRIP

SHOP JIG

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