cabinet, a docutorial how to

[sao95]

the bookshelf/curio cabinet I'm building now, finally started to get some stuff done on it, I figured I give ya a play by play with lots of pics, mainly because I really bored :rolleyes:

first thing, draw it out, just a two dimensional to get the proportions
http://img99.imageshack.us/img99/8424/cabdrawnb7.jpg

the doors on left and right are a bit small, but it was the only option because of the size of the books to be put on the shelves, all the shelves will be adjustable, pull outs on the left and right side, glass doors in the center top with lights and glass shelves, cabinet made out of white oak, the center section will stick out about 6 inches from the sides so that it isn't totally flat, and the center doors and raised panel sides will be arched to make it more inviting, finish isn't decided yet. When you get the lumber rough order 15% more board feet than you figure because you'll have to cut out knots, cracks and other rough spots. Right now the materials are figured at around $2000

so starting with the raised panel sides (btw, stiles are pieces that run vertically holding the raised panel, rails run horizontally)

rip the stile and rail material about 1/4" wider than finished product, you can make stile and rails with a router and run of the mill bits and a table saw, it would be hard to eaplain though, I'm using a stile and rail bit set for a router on a homemade router table. (which can be made with a few 2x4's, piece of plywood, all-thread and wing nuts for the fence. back of the stile profile typically should be about 3/16"
http://img92.imageshack.us/img92/6419/cabinet019ng1.jpg
this is what it looks like after it ran
http://img96.imageshack.us/img96/1529/cabinet022cb0.jpg

oak has a tendency to flake when you shape it, which is one of the reasons why you leave it wide, after the first run if it flakes, run it again and since it's not taking as much meat out it'll take the bit better, this is a rail with both sides done for a panel to go top and bottom
http://img97.imageshack.us/img97/1296/cabinet024gc1.jpg

also started glueing up panels, I make em about 2" bigger width and length than the final product. titebond will work, but gorilla gluw works better, it's all that I use it on is the panels, the rest I use titebond, but the panels are weaker so use gorilla glue. lay them out then mark then In and Out (for jointer) or up and down (for table saw, a table saw will work, but a jointer does a better job), the in faces the fence, the out faces away from the fence, since no blade cuts perfectly, doing this makes a better joint. also the wood grain should arch diferently for each piece (look at the end of the board for the arch) , up, then down, then up, et cetera, helps to keep it from warping,

http://img98.imageshack.us/img98/364/cabinet011dy5.jpg

then wipe them with a damp rag, put a bead of glue on and smear a good layer over the entire edge, then clamp them together, clamps on top and bottom to keep them from bowing in the clamps

http://img152.imageshack.us/img152/9267/cabinet018hr3.jpg
http://img83.imageshack.us/img83/8524/cabinet014tw7.jpg


let the glue dry, then scrape the excess off
http://img223.imageshack.us/img223/9337/cabinet016xk1.jpg

now the panels will get planed down to 5/8" so that they fit in the stile profile without sticking out

that all comes in the next installment of this docutorial....

[Don-Dad]

I'm looking for something like that for my basement. I'm no woodworker though. Probably going to buy some unfinished cabinets and book shelves and piece it all together.

[sao95]

hey I deliver :p

[Will'sdad]

Good work Norm! Seriously, I wish I could do that.

[Becca's Dad]

Wow Sao, that looks like an amazing piece. I built a bookshelf for paperbacks once (plans were in a book on owning a used bookstore) but I don't think I could tackle something that complex. Good Luck! Can't wait to see the pics.

[woodchuck]

Do you use biscuits for edge joining or just glue?

[sao95]

don't use biscuits, the panels don't actually support any weight so it's not needed, if it was needed though I'd use dowels, they are alot stronger ;)

Will, that's what this docutorial is for, so you can learn to do it ;)

little progress made today, demands of the spouse and all that, but here we go :)

okay starting the arch and running the stile cut on it, first lay the arch out to scale, this is on a sheet of 1/4" plywood.
http://img147.imageshack.us/img147/3676/cab2002xo3.jpg

now using a piece of plywood, draw the arc, cut it to about 1/8" inch from the line, then sand it to the line, make sure it is very smooth as any bumps will look worse with the profile, I hate to admit it but I had to make two, I screwed the first one up.. oh and make sure the plywood is longer than the piece, it gives you a handle to hang on to...
http://img118.imageshack.us/img118/7977/cab2004iy6.jpg
http://img118.imageshack.us/img118/4281/cab2005og8.jpg

now draw on the lumber you are going to use and cut it about an 1/8" from the line, but don't sand it, you screw the plywood on top so that the arch matches the pencil line and the plywood will run on the router bits bearing, so it'll clean up the rest for ya, also go with the bit a few times to take off some of the excess, that way when you run against the bit for the final cut it has less of a chance of chipping
http://img82.imageshack.us/img82/3134/cab2006fm5.jpg
http://img137.imageshack.us/img137/4015/cab2008mb9.jpg
then cut to size
http://img137.imageshack.us/img137/6807/cab2010vk3.jpg

so the arches are done, the stiles are ran, all that's left is to put the rail cut on and run the panels, after the panels were dry and scraped, I took them down to 5/8"
then cut them down to size, first joint and edge so that it's straight, then rip it to width, then square the ends to length. Things to think about are if the panels are setting on top of each other do you want the seams to match up, kinda a pain, and really not important as after the finish it won't be noticable...
http://img153.imageshack.us/img153/1537/cab2016zk2.jpg

not as much as I hoped to get done today, but the arches take quite abit of time, also setting up the bits, I had to router a groove in the router table to run the rail cut on the rails
http://img153.imageshack.us/img153/6521/cab2017ll4.jpg

it's just about setup so tomorrow I should have some raised panel goodness to post ;)

[Jackson's Dad]

And remember your most important tool, your Norm Abram's branded safety glasses.

[Bollux]

lol i could only wish i was that talented with wood. but then again helps to have the space the tools and the time. all of which i don't have

[Patrickz]

Damn SAO that is going to be sweet when you finish. I have been wanting to build a headboard and frame for our bed for the longest time. And a couple of nightstands to match. Like Boullox just no time!

[sao95]

thanks Louis :)

can't find my safety glasses :oops:

Not to start a debate, but I don't believe in talent, there's just the things you learn to do ;) I had never heard of most of this stuff until the wife and I got into a fight :roll: before kids, hadn't been living together long, and I had just dropped outta college, and quit my job :oops: went to an interview at a lumber yard, my construction knowledge and college (3 years at that time) gave me the in for a QC job, pay would have been more than I had ever made before, went to the first interview and I got along with the guy, one of those where you know you'll get the second interview, well a week went by, wife got real bitchy, I kept sayin, it's only a week, it takes time sometimes for them to get back to ya, she kept bitchin, there was some yellin, and I said "fine I'll get a job tomorrow", she didn't think I could, I opened the paper and called the first framing job there was, went in to interview and it was a cabinet shop, newspaper made a booboo, but they needed help bad, said "do you think you can do it", in my brain I thought, no, but I have to get a job today to show her I can, so I said "yep no prob". 2 days later I got the call for the second interview, wife got excited until I told her "I have a job, making 1/3 of what I would have made there, and I'm not quitting, I already accepted the job". She was pissed :D heard about it for a long time, but I have to admit, what I didn't get in money I got in knowledge ;) (sorry, that was a long story)

I have a headboard to make as well Pat, post pics when you start, and pm me if you need help :)


alright, here we go, lots of pictures today

run the rail cut on the rails, there are a few ways to do this, use a miter gauge, which is what I had planned on doing but the one I have gives about 1/64, which makes the cut about 1/32 off, or you can screw a piece od plywood to it and run it on the bearing/fence, which is what I did, leaves scew holes but they are in the back of the panel. Also you want it to match up to the stiles cut so that when the pieces are put together they are flush on top, maybe a 1/32 off, but more than that = alot of sanding
http://img54.imageshack.us/img54/8489/cab3002as2.jpg
http://img215.imageshack.us/img215/1857/cab3006uv5.jpg
http://img215.imageshack.us/img215/1238/cab3005ew0.jpg

now on the the panels :) you can make panels on a table saw or radial arm saw, or buy a bit, this is a beautiful bit, never used it before, I probably would have left the panels 1/16 thicker if I knew how it ran, but oh well, you can run the panels on the bits bearing, but if the lumber chips out on the side whatever gash is in the side will show on the panel profile, so takeoff just a little and keep bringing the bit up, it took about 8 runs to do the panels... also, for each run, run against the grain then withthe grain, it helps to keep it from chipping on the ends, I ran mine using a fence and the bearing, and I did get a chip in one, but the fence saved the work ;)
http://img109.imageshack.us/img109/6476/cab3008tq8.jpg
http://img223.imageshack.us/img223/4614/cab3011au3.jpg

you notice I didn't put the arch in a panel to match the stile, I forgot :oops: no biggy, just take the stile arch that will go with the panel, mark it with a pencel, then cut and sand as done before with the plywood template, only this time you'll sand wood to the line, make sure it is really really smooth on the edge or if your running it on the bearing it'll show
http://img80.imageshack.us/img80/3452/cab3017at5.jpg

now you glue it all together, lay the sides on barclamps, mark where the rails will be, then start from left or right and glue the rails in, while placing the panels in as you go, be liberal with the glue, but have a wet rag to wipe of what runs out
http://img127.imageshack.us/img127/3369/cab3018be6.jpg
http://img86.imageshack.us/img86/5524/cab3026gp9.jpg

cont. (20 image limit)

[sao95]

now put some glue on the tops of the rails and put the other side on, lay it in the clamps and clamp it together, use a piece of wood and hammer to knock the rails where they need to go if they are a bit off, usually when you glue and clamp the panels are facing down so you can nail the back without unclamping it, but I had changed a few dimensions from the original drawings so had to glue it face up, then flip it, reclamp and nail, 2 or 3 nails through the tongue of the rails is enough
http://img73.imageshack.us/img73/9452/cab3019rh6.jpg
http://img153.imageshack.us/img153/1975/cab3022yr5.jpg

forgot to mention, before you nail it, measure from corners to make sure it's square, if it's not use a clamp across on the big side, or take a hammer and beat the crap outta it ;) I didn't have a clamp long enough so I went route 2
http://img125.imageshack.us/img125/9030/cab3021ck3.jpg
that's a shadow going across the top
http://img291.imageshack.us/img291/3246/cab3025rg6.jpg
http://img157.imageshack.us/img157/9458/cab3028wz1.jpg

lots of sanding still to do, but it comes later, also have to chop the top to size

lock miters and face frames soon to come...

[jeffus]

Holy Snikey! :shock: Man knows how to handle his wood!

All bow to NORM! :prayer: We're not worthy!

And he wonders what to do with his life?

[Bollux]

sweet bahjesus....now that boy has skillz

[Patrickz]

Holy Snikey! :shock: Man knows how to handle his wood!


He said handle his wood!!

Nice work SAO. That bit is sweet too!

[dabrewinguy]

Very nice work indeed! I have lots of projects like that one in my head, and in a sketch book. In fact that piece you're making looks alot like what I want to put in my basement. I mainly want to use it as a liquor cabinet though, with locking doors and that fancy wire mesh so you can see into it. I've been slowly expanding the tool collection in the workshop, so in time I'll have all the right tools for the job. Congrat's on a job well done so far!

[sao95]

I had to learn to handle my wood, cause my wife doesn't handle it enough :lol:

forgot to mention those are the sides, if your looking at the panels and wondering why one side stile is bigger than the other, because it will get lock mitered and then have a routered 5/8th edge, so when it's done it'll look equal ;)

that's what I did as well DBG (brewingguy), it took along time to get the tools I have, and I've always bought things I needed for jobs, so I have alot of tools that I rarely use, but needed at the time so buying other tools I wanted was put on hold. and then stuff breaks, or I run over it with my truck :roll: (ya I'm an idiot) or it gets stolen on a jobsite, or I send my brother out to clean the shed when moving from Texas and he doesn't see the bullfloat :wall: (which I've already needed recently) so then you gotta rebuy the stuff :plasma: and don't even get me started on loaning stuff out!! I don't even do it anymore, regardless of friendship, family, I don't care. There's a guy in Texas with my six sets of roof jacks :mad: ironically he made sure to stop by when I wasn't home and pick up his floor jack.

that turned into a rant :oops:

anyone else have a problem buying tools, the wife givin ya a hard time that is, even when you need them for the house or something. My wife seems to think that tools are my special treats, which in a way they are, because it makes it easier to do stuff with the right tools, and because I appeciate a good quality tool, but it's not considered something we need, it's something special for me. That drives me crazy. hello, I'm building crap for you, and fixing up our house. But if she buys scrubs for work, that's not new clothes for her, it's not her special treat, it's clothes she needs for work. Kinda a double standard that really irritates me :mad:

[woodchuck]

Looking good, how easy does that Gorilla glue squeeze out come off, you just use an old chisel or putty knife? Are you using a drum sander of sorts for sanding to the line on the radii of the panel?

I'm pretty lucky in the tool department, if I really need it, she says "get it", but I try not to buy tools for a one time job, more for extended use over the years or renting, I don't have the guts to have a nice table saw show up here yet, too much$. The little paying jobs I get are helping the 'cookie jar' tool fund though.

[dabrewinguy]

Oh, I don't loan out tools anymore either, unless I get a security deposit of either a case of beer or a bottle of JD. And I only loan things to people I trust and that I know will take good care of my stuff. I usually don't get too much crap from the wife about buying tools unless they happen to be over $200. Only the really expensive stuff needs to be justified. I've wanted to upgrade my table saw for a while now, but since the guy across the street gave me his, (which was nicer than what I had) now I'm stuck using that one for a while. I think next on my list of things to get is a thickness planer so I can start working with raw cut wood.

[Weston]

Those panels are gorgeous! You can call something like that gorgeous right?

You definitely need to do that FT whenever you do go back to work FT

[sao95]

Looking good, how easy does that Gorilla glue squeeze out come off, you just use an old chisel or putty knife? Are you using a drum sander of sorts for sanding to the line on the radii of the panel?


it comes off pretty easy, when it dries it looks like foam, it's kinda weird looking, I found a painters scraper like in the pic below works best, it doesn't scar the wood to bad, and you can do it quickly, a putty knife works, but it's not easy. I wish I had a drum sander, it's on the list of "need to gets", but haven't been able to swing it yet, so for now I am using a craftsman bit made for drill or drillpress, it might work in a router, I haven't tried it, not sure if the sandpaper could handle the rpm though, it's in the pic below as well, and the sandpaper can be changed. I was surprised at how well it worked, basically when you get close to the line you want to go in one fluid motion, fairly quickly, from one side to the other, it takes off the high spots and does a fairly good job of smoothing it out, didn't really take much hand sanding at all :)

http://img262.imageshack.us/img262/8279/p1010001xw0.jpg

DBW, if your talking really raw lumber you'll need a jointer/face planer before the thickness planer, the jointer will true the board, a thickness planer won't. really you need both, but if your only working with semi-raw lumber, like s3s (sufaced 3 sides) which still has bad spots in it, you might be able to get away with just a planer, I think I'd still go with the jointer though ;)

I really want to just get a small shop going, have a pole barn by the house, work everyday when the kids are in school and be home when they get home, that would be ideal.

[woodchuck]

A surface/thickness planer is nice, I have a DeWalt 12-1/2", but a good 6" joiner with a long bed is the first step.

For me, working with raw wood starts with the chainsaw to rip a log into boards, then get one good face, then an edge, the planer does the second face and the table saw takes care of the final cut.

My wishlist includes a 'real' tablesaw, a nice 6" joiner(air craft carrier), bandsaw that can resaw well, floor drill press.

Some cheap wood that comes out nice is crating lumber, sometimes have to cut out defects, but there is quite a lot of it free for the taking if you look around. A horizontal drum sander would be ideal for cleaning this stuff up but a belt sander would do just fine also.

[sao95]

For me, working with raw wood starts with the chainsaw to rip a log into boards, then get one good face, then an edge, the planer does the second face and the table saw takes care of the final cut.
.

the doors we made had to be trued like that as the timber we used was totally raw when we got it.
I need a nice drillpress and bandsaw as well, but right now a jigsaw and drill work with a little extra effort, a big horizonal drum sander? are you talking the kind that feeds the lumber through like a planer, the larger wide belt sanders are reallly really nice :D
http://www.woodmastertools.com/Images/DrumSander.jpg
or the long tables? can't find a picture of one :( the belt is like 6"X60", they are great for sanding things that are curved or circular...
both are nice to have :D

[sao95]

an update, haven't had time to work on it, but the basic structures are built. they will connected with brass screws from the sides to fit the trim and doors, taken apart and sprayed, then reassembled in the home (otherwise it wouldn't fit in the door). The two sides will have adjustable shelves, the bottoms will be raised panel doors, the center middle will have glass doors, the center top is for books (the guy wanted it, not sure how crazy I am about it). The right side top you see a curved piece, that needs done a few more places, crown molding and trim on the bottom which will support the weight and lift the whole thing 3 inches from how it sits now, the edges will be routered in places, and the other tidbits...
http://img136.imageshack.us/img136/4770/cab6002or7.jpg

bad picture, but the lock miter I mentioned looks like this, it has the nice seam of a 45 degree joint, with alot of strength
http://img237.imageshack.us/img237/2770/cab4012bl6.jpg

and the face frames are doweled for extra strength...
http://img201.imageshack.us/img201/6954/cab4003si5.jpg

face frame lock mitered to the side panel
http://img86.imageshack.us/img86/1134/cab4018hc1.jpg

[sao95]

an update, still alot of sanding and a few tidbits like hinge the doors
http://img72.imageshack.us/img72/9691/cab8007la4.jpg
http://img224.imageshack.us/img224/439/cab8009sz8.jpg

putting a piece of trim on I shot a nail into my finger, it hit bone and I think it's broke :roll: didn't hurt bad when I was workin, but now that I'm sittin, DAMN!!!!!

[SGTDad]

Wow, that looks nice! That sucks about your finger - I hope it turns out ok!

[jeffus]

Wow! Nice Work!

And Ouch! Hope you're OK!

[Riggs]

That's awesome! Maybe it's good I've never sprung for that nailer I wanted. Bummer!!!!!

[Bollux]

dude, thats unreal. nice job

[stretch]

Amazing job!

Sorry about the damaged digit. Hope it wasn't your communicating finger.

[Weston]

Quite a piece of artwork!

[sao95]

thanks :) I am gonna get a Tetanus shot today just to be on the safe side, it's been 20 years or so since my last :oops:

[SideShowCecil]

Yowch! That sounds painful.

Funny how injuries never seem that bad while you’re working but a few hours later or the next day the full extent of the damage sets in.

Last week I hurt my hand when my drill slipped off the screw I was driving. I just wrapped a paper towel around it and kept working. Later that evening I realised I drove the driver bit almost completely through the skin between my thumb and forefinger. It HURT LIKE HELL and my thumb was pretty swelled up.

My last tetanus shot was two years ago when I got a half dozen stitches in the same thumb.

[DarthDaddy]

THAT IS JUST UNBELEIVABLE!!!!! WOW I am Very Impressed...Very Impressed!!!


Sucks on the Finger... Actually if they give the shot right it should not hurt. I just had one when I had the bike fall. Granted the pain on the other elbow probably masked the pain from the shot!

So when are you making one for me... I will come pick it up... I am soooo very impressed!!!!!

:hail::hail::hail::hail::hail::hail::hail::hail::h ail::hail::hail::hail:

[sao95]

thanks Darth :) and since your only in chicago I'd drive it up and install it ;)

[sao95]

sprayed the cabinet with stain tonight, one of the bad things about being a sahd. Some things you just can't do with a kid in tow, because the stain will dry, so you can't get interrupted, and can't risk the little one walkin out and getting a big whiff of the fumes, so you wait til night, but the lighting sucks and the garage door has to be down so the compressor doesn't bother the neighbors. What I wouldn't give for a pole barn in the country, and lots of lights. So I guess tomorrow we'll see if I sprayed it fairly uniformly :oops: I couldn't see very well so I was going by feel:doh:

[Patrickz]

Nice SAO!
That is what I am thinking about for my head board unit in looks. The shelves and cabnet on the side with the king size bed in the middle.

[sao95]

how tall are you gonna have the headboard/shelves? Will the headboard have shelves as well?

[sao95]

okay on my wish list add a bigger compressor, I'm clear coating right now and it has to be sprayed at 80psi, I have a 15 gal 150psi compressor, I have to stop after 2 minutes of spraying and wait 10 minutes :wall: it doesn't help that there is only one outlet in the garage and on that line is all the kitchen, it blows alot :wtf:

pm coming your way pat

[sao95]

F&CK!!! my compressor just died on me I HATE CRAFTSMAN!!!!!!!!!!!!!!!!

[sao95]

well a chewed up pistin and housing and broken head valve = new o-ring 3 bucks, head valve 12 bucks, piston and housing 27 bucks, head gasket 7 bucks, shipping 15 bucks:doh: :wtf: :bs: :bs:

[Patrickz]

how tall are you gonna have the headboard/shelves? Will the headboard have shelves as well?

I think the shelves should be on the sides only but then maybe one long one on the top?... Can't decide really. The wall it will go against is pitched to 12' or better from 8'. Maybe it should just be in pieces? hmm.

[Patrickz]

well a chewed up pistin and housing and broken head valve = new o-ring 3 bucks, head valve 12 bucks, piston and housing 27 bucks, head gasket 7 bucks, shipping 15 bucks:doh: :wtf: :bs: :bs:

Get a new Rand.. ;) for the money.

[housedude]

sao I feel for ya man. Sometimes it seems like you spend more time working on broken tools and jigs than actually making the project that the tools are used for:mad:

BTW The unit looks awesome (aw man that sounded funny)

[sao95]

damn sears :mad: they called to let me know they didn't send out my parts :axe: I had to pay with a credit card and I decided to use my sears card, but I had never activated it, I asked the lady "do I need to activate it and call you back", she said "no, since it's a sears card it'll be fine". I just cancelled the parts and I'm gonna look for a Campbell Hausfield motor at tractor supply to throw on my tank....

[sao95]

couldn't find a motor, so I activated the card and reordered the parts :oops: truthfully I just didn't feel like going to stores and running all day looking for something :roll:

[sao95]

woot, compressor up and goin again :)

[sao95]

alright last update, the cabinet is done, FINALLY :oops: installed with the glass, the glass took 2 weeks as they screwed up the cut the first time, I still wasn't real happy with their work, but I was over it. Only thing I had all the hardware in a huggies wipes container, but somehow forgot the lock and key strike, so I have to put that on sometime, but here's the pics. Overall it turned out all right, and I like the lights, they are on a dimmer hooked to the hinge so you just touch the hinge to turn em on and off.

http://www.dadstayshome.com/dads/imagehosting/3034552beff348d1.jpg

http://www.dadstayshome.com/dads/imagehosting/3034552bf5962565.jpg

http://www.dadstayshome.com/dads/imagehosting/3034552bf5985012.jpg

http://www.dadstayshome.com/dads/imagehosting/3034552bf59a3088.jpg

oh the black cords on the center top shelf are the lights/transformers/dimmer, but they are hidden when the books are put in
http://www.dadstayshome.com/dads/imagehosting/3034552c0059401a.jpg

[Weston]

Nice! :hail:

[jeffus]

That's awesome! Nice Work!

[Don-Dad]

sweet, I really need one of those for my basement. Nice work!

[MIDAD]

Only thing I had all the hardware in a huggies wipes container,



:lol: :lol: :lol: :lol: ...Those suckers are handy, aint they?
Great job....you definitely have a talent with woodworking...:wtg:

[Riggs]

To quote our 4 year old, "Cool."

He said he'd use it for a fort, maybe sleep in the cabinets.

I agree, cool. =D>

[Mr. flip]

anyone else have a problem buying tools, the wife givin ya a hard time that is, even when you need them for the house or something. My wife seems to think that tools are my special treats, which in a way they are, because it makes it easier to do stuff with the right tools, and because I appeciate a good quality tool, but it's not considered something we need, it's something special for me. That drives me crazy. hello, I'm building crap for you, and fixing up our house. But if she buys scrubs for work, that's not new clothes for her, it's not her special treat, it's clothes she needs for work. Kinda a double standard that really irritates me :mad:

SAO I feel your pain, over the years it's been like pulling teeth with trying to buy tools. I either have to wait for Christmas, birthdays, or maybe even Father's day to get any tool love. Even then I usually have to compromise from what I need (or want :D ) with what the wife thinks I need or want. By the way your project looks awesome. chugchug: CHEERS!

[sao95]

thanks all :)