I was telling people that it was over 400 holes, but though the drawers are about 27×22, the actual grid for the pot separators in the bottoms of these drawers is only 16×22. Still, the enormity of just how many holes I’d set myself up to drill only sunk in after the first hundred. I’d clamped two of these together with a sheet of pegboard on top for stability, and used 1½” of maple block drilled out on the drill press to keep my bit vertical. I put it on a sheet of cheap ply to help reduce tear-out, but if I ever do this again (and haven’t built a CNC router to do it with), I’ll not only clamp the bottom layer in too, but I’ll also use a brad point bit.
However, the bottoms will be hidden, so that’s okay. Need to hit ‘em with the 220 grit sandpaper, and a coat or three of poly, and then we have pot drawers in the kitchen. Separators will be ¼” steel rod.
-- Dan Lyke, Petaluma California, http://www.flutterby.net/User:DanLyke