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First Cabinet #1: A Brief Walk Through

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Blog entry by DonLumberJohnson posted 07-09-2013 06:36 AM 774 reads 0 times favorited 0 comments Add to Favorites Watch
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This will be a sparse outline of an Incra Router Cabinet Build.

I know it’s a blog but am going to open with a review anyway.

My initial impression of the LS-25 Super System was positive. The stand and table have substantial weight together and seem stable enough right out of the box.

The LS-25 deserves a review all on it’s own. I love the system bunches and hate it a little too. Just like any good relationship should be.

Pros – Almost zero learning curve, accurate, repeatable, awesome fine adjustment and it freaking looks like its from the year 2424. I would not be doing half the router work I am doing without it. A large can of confidence comes in the box plus some on the DVD and instructional booklet.

Cons (still worth it) – Nothing was square out of the box. I ran out of the factory provided shims and resorted to blue tape multiple places on my beautiful machine. Functionality wins every time. The bottom of both fences in this system need to be covered with slick tape anywhere they meet the table.

Out of the box it looks like this:

I did a rough drawing to start, measured the rough dimensions of one side of the stand and started cutting. Looking back I would have measured better and started cutting later. The face frame you see only has two pieces of the original. I seem to have forgotten 1/2 inch in the width somewhere.

Throughout this you will read about my shortcomings. I am not an elitist jack wagon that never makes mistakes, so deal with it. I am also new to this sport and not trying to be an elitist poser, rather learn from and excel past elitist posers. That’s my 2-cent soap box … moving on.

The face frame is solid birch. I happened to find some nicely figured birch at the local H.D. and bought it all. The joinery is about 8 pairs of mortice and tenon. The mortices were cut with a Freud 1/4” Spiral Up Cut Bit. The shoulders for the tenons were cut on a table saw and the tenons with a Freud 1/2” bottom bearing patten bit and rounded to fit the mortices.

The opposite, back face of the cabinet is 1/2 inch birch plywood cut to fit.

If you have an LS Super System you will notice that I have moved the 2 1/2 inch vacuum port to the opposite side. The plan is to put a 4 inch vacuum port in the router box and tie the 2 1/2 inch port into the box as well, both on the same side.

Honestly that sounds horrible but I can’t think of any other way to get er done. Suggestions are appreciated….

Once the front and back were installed the next logical progression was to install slides, and make a drawer to fit. The slides are Richelieu full extension 16 inch ball bearing slides with face frame adapters that attach to the back of each slide. I won’t go into the details of installing the slides, I am sure I did it wrong because it was a serious pain in the back side. The drawer went together perfectly the first time after following the Incra setup method for half blind dove tails, DOVN cut with a Freud 1/2, 14* dovetail bit (DR22104).

One note here, I was going to make the drawer out of 1/2 inch plywood. Dovetail bits chew up plywood in a bad way so I decided on hardwood. That drawer in red oak cost me 57 bucks not including the slide or handles.

Another note, the red oak Lowes sells is not the size it is advertized to be. No lectureing about duh, a 2 by 4 isn’t really 2 by 4 either because I already know that. The 3/4 by 8 red oak is really 3/4 by 7, 1/4”. I think wood sold at that price should be what they say it is. New rule – we need to stop calling a 2 by 4 a 2 by 4 because it isn’t 2 by 4.

The slides attach to the face frame and back like this:

This is what a 57 dollar drawer looks like:

Notice there is only one drawer so far …. no moolah

This is the DOVN template in half blind fashion:

The router box is tied in to the frame and back and made of 1/2 inch birch plywood framed in on two sides with Solid birch. The window frame on each side is put together like a picture frame, 45 degree mitered cuts glued with Elmer Pro Bond, solid as a rock so far. I made a test frame out of scraps, my kid have yet to break it throwing knives and rocks at it. The frames are made of Birch molding made with the LS and a Freud Roman Ogee bit. The window it’s self is 1/4 inch plexiglass epoxied to the wood. The frames attach to the cabinet with 0.3 by .11 neodymium disk magnets set in the wood with opposing poles.

Router Box:

Magnets to hold the window:

Window:

That’s my project so far. I will try to update with pictures of the remaining drawers as they come into existence.

I am seriously nervous about finishing it so suggestions would be appreciated.

My thoughts so far are danish oil and wipe on polyurethane or shellack.

-- Don, Roanoke VA



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