Tuesday, December 18, 2007

Progress Update, and A Quick Trip to the Lumber Yard

I thought I would take a few minutes to review the check list from the So Just How Do You Make a Corner Cabinet? post & show how far I've come with this project and how that list has actually changed. After all, the list of steps in that posting was just a best guess as to how everything would go. Since I haven't printed that list out and checking things off as I went, I'll go through it all now.

What I'm going to do is go through the list, step by step, and add "Done" to the step if it's done. Things will get moved around if the order has changed, and there will be more explanation about steps that got deleted & replaced by others.

OK, here we go!

  1. Make pattern for Top / Bottom Shelves -- Done
  2. Cross-cut blanks for Top / Bottom Shelves to rough length -- Done
  3. Cross-cut blanks for Wide Backs to rough width -- Done
  4. Rip blanks for Top / Bottom shelves to rough width -- Done
  5. Rip blanks for Wide Backs to rough width -- Done
  6. Lay out over-sized shape of Top / Bottom shelf on each blank -- Done
  7. Cut Top / Bottom shelves to rough size & shape -- Done
  8. Use router with pattern bit to cut Top / Bottom shelves to final size & shape -- Done
  9. Plane stock for Base Cabinet Sides to thickness -- Done
  10. Rip Sides for both cabinets to rough width -- This and the next couple of steps didn't go so well. If you recall, the splitter on my table saw was out of alignment with the blade, and I had to go to Woodcraft and use their machines to straighten everything.
  11. Rip Face Frame Stiles to rough width -- Done
  12. Rip Face Frame Rails to final width -- Done
  13. Cross cut Base Cabinet Sides and Face Frame Stiles to final length -- Done
  14. Cross cut Upper Cabinet Sides and Face Frame Stiles to final length -- Done
  15. Cut all rabbets (Top / Bottom Shelves. Base Cabinet Sides, Upper Cabinet Sides) -- Done
  16. Cut all dadoes (Base Cabinet Sides, Upper Cabinet Sides) -- Done
  17. Fit Sides to Base Cabinet -- Done
  18. Fit Sides to Upper Cabinet -- Done
  19. Set bevel angle on table saw to 22.5° using Wixey & scraps to fine tune -- This step was deleted
  20. Rip Sides to final width -- Done
  21. Rip Face Frame Stiles to final width -- Done
  22. Reset blade to 90° -- This step was replaced with: Cut birds mouth joints in Sides
  23. Lay out Face Frame Rails -- Done
  24. Cut all Face Frame Rails to final length -- Done
  25. Fit Wide Backs to Base Cabinet -- Done
  26. Fit Wide Backs to Upper Cabinet -- Done
  27. Set blade to 45° using Wixey & scraps to fine tune -- Done
  28. Rip Wide Backs to final width (beveled cut) -- Swapped steps 28 & 29. Done
  29. Rip Base Cabinet Narrow Back & Upper Cabinet Narrow Back to width (blade still set to 45°) -- Done
  30. Dry fit Base Cabinet -- Done
  31. Fine tune joints -- Done
  32. Dry fit Upper Cabinet -- Done
  33. Fine tune joints -- Done
  34. Reset blade to 90° -- Done
  35. Cut Foot Blanks to rough width & length -- Done
  36. Glue up Feet from the Foot Blanks, 4 blanks to a foot. -- Done
  37. Rip Feet to final dimensions -- Done
  38. Drill hole for leg levelers in all blanks for the Base Cabinet -- Done
  39. Glue Feet to the Bottom Shelves -- Done
  40. Extend leg leveler hole through the Base Cabinet Bottom Shelf -- Done
  41. Install leg levelers -- Done
  42. Drill shelf pin holes in Sides & Wide Backs -- Done
  43. Glue up Base Cabinet -- Done
  44. Glue up Upper Cabinet -- Done
  45. Cut the three Base Cabinet Top pieces to final width & rough length (best if I can get them from one piece)
  46. Route all molding profiles
  47. Cut arc in bottom of Base Board -- Done
  48. Set bevel angle on table saw to 22.5° using Wixey & scraps to fine tune -- Rather than change the bevel angle of the saw, I just used my Osborne EB3 miter gauge set to 22.5° & raised the blade to full height.
  49. Fit & miter moldings to Base Cabinet
  50. Glue & brad moldings to Base Cabinet
  51. Fit & miter Base Cabinet Top pieces
  52. Glue & brad Base Cabinet Top pieces to Base Cabinet
  53. Fit & miter moldings to Upper Cabinet
  54. Rip blanks for Adjustable Shelves to rough width
  55. Make pattern for Adjustable Shelves
  56. Cross cut blanks for Adjustable Shelves to rough length
  57. Lay out shape of Adjustable Shelf on each blank
  58. Cut Adjustable Shelves to rough size & shape
  59. Use router with pattern bit to cut Adjustable Shelves to final size & shape.
  60. Cut Adjustable Shelf Edging to final width & rough length
  61. Cut rabbet on front edge of Adjustable Shelves
  62. Cut rabbet on Adjustable Shelf Edging
  63. Fit Adjustable Shelf Edging to Adjustable Shelves (ends have 45° miters)
  64. Finish Base Cabinet, Upper Cabinet and Adjustable Shelves
  65. Install Base & Upper Cabinets in dining room
  66. Cut blanks for Lower Door Panel to rough width & length
  67. Glue up blanks for Lower Door Panel
  68. Cut blanks for Upper Door Panel to rough width & length
  69. Glue up blanks for Upper Door Panel
  70. Cut Lower Door Stiles to final width & rough length
  71. Cut Upper Door Stiles to final width & rough length
  72. Cut all Door Rails to final width & length
  73. Cut curve in Upper Door Top Rail
  74. Cut grooves in all Lower Door Rail & Stiles
  75. Cut grooves in both Upper Door Stiles & the Upper Door Bottom Rail
  76. Cut deeper groove in Upper Door Top Rail
  77. Cut arch in Upper Door Top Rail & sand smooth
  78. Cut stub tenons on the ends of all Door Rails
  79. Cut decorative grooves in Upper & Lower Door Panels
  80. Dry fit Lower Door
  81. Fine tune joints
  82. Dry fit Upper Door
  83. Fine tune joints
  84. Glue up Lower Door
  85. Glue up Upper Door
  86. Cut Lower Door Stiles to finish length
  87. Cut Upper Door Stiles to finish length
  88. Make Door Bead Edge Molding
  89. Set blade to 45° using Wixey & scraps to fine tune
  90. Fit & miter Door Bead Edge Molding to Lower Door
  91. Glue & brad Door Bead Edge Molding to Lower Door
  92. Fit & miter Door Bead Edge Molding to Upper Door
  93. Glue & brad Door Bead Edge Molding to Upper Door
  94. Finish doors
  95. Mount hinges to doors
  96. Mount doors to cabinets
  97. Mount Knobs to doors
  98. Mount doors to Cabinets
  99. Mount door catches

You can see we're slightly more than 1/2 done, and I still have to route molding profiles & miter them. To that end, I stopped at Condon's at lunch on Tuesday & bought a 5/4 white oak board to make my crown moldings & ogee molding from. The board was 5" wide by 10' long, about 5 bd ft. Since I had my car & not the van, I had them cut it in half before I took it home. So now it's two boards 5" wide by about 5' long.

The reason I bought this extra boards is because the stuff I got from Lakeshore is cut a little too close to final size for me to feel comfortable cutting these moldings. My fingers are probably going to be just a little bit too close to the bit if I try to route the profiles into these boards.

So I hope to get up to Wood Craft again one day next week, after Christmas, and rip the two halves in half, then joint & plane them square. Then I'll be able to take them home & route my profiles.

I'm probably not going to get any work done on the cabinet, and I'm probably not going to post anything more until after Christmas. So for all those who celebrate, let me take a moment to wish you all a Merry & Holy Christmas!

2 comments:

neil said...

Hi Tony......

Liked going through the list. I'd forgotten how detailed it was.

After starting, did you add any steps to the procedure sheet???

Very Interesting to see......Neil

Tony V said...

Neil:

You're right, I forgot to add a few steps to the list that I actually performed. In the original list, I had nothing about using pocket screws. I used them both to put the face frame together and to attach the carcase to the face frame.

Other than that, I don't believe I added any other steps to the list.

Happy New Year, bro!

Tony