Good progress today. I got all the plywood components rough cut, and cut to finish dimensions.
I only had to stop once for a trip to the store—Wally World $5 plywood blade got dull and needed a replacement. I was starting to get burning and tear-out.
I found out that the local box hardware store, Marvin’s, has Oldham 7 1/4” plywood blades for $1.99 and 10” Oldham plywood blades for $4.99! Score! 5 7 1/4” and 1 10” blade later, it was back to it.
So, the sides, tops, bottoms, and shelves are all cut to final dimensions, cleaned up the shop, and laid out the dadoes for the box construction. Tomorrow will be cutting the face frames and figuring out the best way to rout the dadoes. They’re pretty close to the ends of the side panels, and I don’t have a sliding crosscut sled yet; the plywood, naturally, isn’t 3/4”—it’s 23/32”. I can’t just chuck up a 3/4 straight bit and be done. I’m thinking of clamping a guide and cutting the pass closest to the end, then shifting the guide back to complete the cut. Using the stacking dado blade on the table saw would be the most efficient way to do it, but without an effective way to support the panels, I’m not going to risk it.
For box construction I think I’m going to glue and screw the tops and bottoms to the sides, then plug the holes. If I hold my lips right, I should be able to get a good grain match. The plywood has a pretty broad grain, and I think there’s enough scrap to do it. Plus, with only one end panel showing, it should be a snap.
We also need to match the color of the existing cabinets. I think I see myself taking off a door or the false front at the sink and going on a quest. I have a feeling it’ll end up at Woodcraft…
Let’s see what tomorrow brings! It’s coming together faster than I thought, but it’ll be real satisfying to see once something’s put together!