mdbuilder Posted January 22, 2011 Report Share Posted January 22, 2011 Moving right along, I started this thing weekend before last with the milling. I did hand cut dovetails. I had ordered a through dovetail template for my PC 4210 jig but it didn't come in until after I needed it, on the other hand I may do a couple more of these so it wil still come in handy. Last week I continued on with the dado's which I plunge cut on my 50 year old Dewalt RAS. Cleaned them up with chisels and a router plane. Marks jig on this weeks video is cool, I pretty much hate my router though . I also clamped up the unglued case and built the drawer to fit the opening. I did the bottom from solid wood and I'll do the same for the case back. This week the hinges came in so it was time for hinge mortises and here my on screw up reared it's ugly head! I took the dimension for the door rails off the drawing, I did measure the case at the time but wasn't thinking. My stock is a 1/16" under 3/4 which means the rail dimension is perfect for a 1/16" gap top and bottom but I should have cut them larger so they filled the space then plane em down later. Anyway, not insurmountable, the doors are square so no trimming needed. It did mean the hinge mortises on the bottom shelf required some high precision depth control so I would get the .062 gap I wanted. The pivot pin "washer" is quite a bit less than .062 so my bottom hinges sit slightly proud of the surface. Once I got the case mortises in I did take my extra rail and cut hinge mortises in that just to make sure I had it right and didn't scrw up the doors All came out well, pretty pleased with it as this type of hinge was a first for me. Took a while but the gaps are consistant on the top / bottom and side. The doors touch in the center when installed on the hinges so that joint will be fit later. I need to groove the top / bottom and sides which I'll do later today then I and ready for glue up. Quote Link to comment Share on other sites More sharing options...
mdbuilder Posted January 24, 2011 Author Report Share Posted January 24, 2011 Last night was time for the glue up. I was a little worried about with my just large enough doors but I set out all the clamps and did a dry run. The case clamped up ever so slightly out of square but one clamp from corner to corner with about turn or so on the handle squared it up so I went ahead. Once I got all the glue applied I set one door panel in place which I knew was square, I added all the clamps then pushed the door firmly against the bottom diver and slide it up to the side. A turn on that diagonal clamp and the door showed the case to be square, I slid the door over to the other side and it was equally nice looking so off to let the glue dry. Once the clamps were off the sliding leg vise I built last month really showed it merits in cleaning up the case. I've got one tail with a prominent gap so I'll have to do something about that. I spent the dayfitting the doors in place which look good with consistant gaps, I back cut the center of each side with a 5 degree back bevel which seems to work well. I used a small chunk of Santos Mahogany to mock up a pull, I think I like it - it is just double stick taped in place at the moment. For door catches I think I will go with some 3/8" diamter rare earth magnets I have in the drawer on the back side of the door. I'm carving and sanding a couple small blocks of walnut to glue in as stops. I'll drill and tap those for about an 8-32 set screw. The magnet will stick to the set screw and the depth adjustment will let me set the door closure where I want it. Quote Link to comment Share on other sites More sharing options...
thewoodwhisperer Posted January 24, 2011 Report Share Posted January 24, 2011 You flew through this man! Nicely done! Thanks for posting your progress. I'm sure this is going to inspire our fellow Guild members. And those doors look fantastic by the way. Quote Link to comment Share on other sites More sharing options...
mdbuilder Posted January 25, 2011 Author Report Share Posted January 25, 2011 Thanks Marc More time spent on the knobs / handles last night, I think I like these. They are just double stick taped in place at the moment so never mind the missalignment! Still need to set up a jig and drill / tap the backs for an 8-32 screw. The right one is sanded through 600 grit, I think I'll wipe on some shellac for a finish, not sure how the oil based poly would work on Sanots Mahogany. Quote Link to comment Share on other sites More sharing options...
mdbuilder Posted January 27, 2011 Author Report Share Posted January 27, 2011 Final details before sanding / filling / finishing. I carved a couple center stop blocks from walnut to hold a 10-32 setscrew for each corner of the doors. The magnets are epoxied in 3/8" diameter shallow holes, blocks drilled and tapped for the set screws. The doors close with a satisfying click as the magnets grab the setscrews. Quote Link to comment Share on other sites More sharing options...
mdbuilder Posted January 31, 2011 Author Report Share Posted January 31, 2011 This weekend iswas time for some finish Quote Link to comment Share on other sites More sharing options...
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