Well we are in the home stretch now on the Pekovich Cabinet. All thats left to do is make the kumiko, fit it in the door, and hang the door. To start the kumiko, I bought a 12" long piece of 12/4 basswood, and used my bandsaw to rip two 9/16 wide strips, then planed them down to 1/2."
I make the grid the way Mike P shows in his Kumiko article in fine woodworking. Its a jig that I clamp to my miter gauge, thats pretty much a box joint jig. The distance between the cross cuts dictates the length and width of the finished kumiko panel. Its important to get this pretty close, test on scrap. I use a flat grind, full kerf blade to cut the grooves for the half laps. I want to mention that its important to use a full kerf blade. My first go around making kumiko, i didnt have one, only a thin kerf blade. The thinner pieces make cutting the angles difficult, and they dont like to hold together. The thicker pieces from the full kerf have more purchase when fit together.
Then rip the individual strips out. I really have to flubber with the fence and scrap to get the fit just right. Its the most challenging part of the process, in my opinion.
Then I cut the pieces to length with a hand saw and saw hook. I skimmed the ends on my shooting board to get them perfect. Then I can fit the grid together.
Then its all about the inner pieces. First do the diagonals. They have 45 degree cuts on both ends. You really have to mess around with your jig to get the stop set just perfect. It is very helpful to have 2 jigs for each angle. Set one to be a little long, then have another jig set to cut the other side of the piece to length. Heres piece in the jig getting chiseled to length.
And all the diagonals fit.
Then cut a bunch of short little pieces and cut 22.5 degree angles on one end of each, with your 22.5 degree jig.
Then on the other end of those pieces, use each of your 67.5 degree jigs to cut the pieces to length. With the 67.5 degree ends, you have to have one side cut deeper so the flat is bigger, its hard to describe ill post a picture of what it looks like.
And those pieces fit together like so-
I put the bigger flats together, im not sure if thats how Mike does it, but it works either way. I didnt take any pictures of the last pieces of the puzzle, but you get the idea now. They are just little short pieces with 45's on both ends, and they lock everything in place. Then after its all fit, pull it back apart piece by piece, and dab a little glue on all the ends, and the grid half laps, and put it back together. I actually did this as I went along, and not all at once. Heres the kumiko panel, before i fit it to the door opening.
I just used a hand plane and shooting board to finesse the kumiko to fit the opening just right. I didnt glue it in, just slip fit it, and called it good. Its not going anywhere.
And here we have it, the Pekovich Cabinet. I hope you enjoyed the journal, and once again, thanks for reading.