Had another quick chance for some shop time and used that to glue together the fitted carcass. I didn’t want to deal with the glueup the day before (after fitting the dividers) as I knew I would need a peace of mind and ample time to do the glueup properly and not rush through it.
And so, I cleared the workbench from all the ‘things’ that always seem to end up on it (how is that always happening?!?) to have use of it’s full length (barely enough) and laid down the carcass sides/top/bottom in their intended orientation upside down so that I can align their edges and then used blue painters tape to keep the parts aligned and together for the glue up.
It’s one thing to flip up taped set of parts for a 6”x4” mitered box, but it’s a whole other experience for a 20”x28” box that stretch far beyond the edges of the workbench from end to end. but somehow I managed it (some tape came off, but I had enough tape to keep things in place so I just had to replace some tap strips here and there when the parts were standing up on their sides on the workbench).
I then managed to slide a sheet of masonite underneath the carcass parts (I know, I should have had it there before I put the carcass parts) to protect the workbench from the glue spills, and I was ready to glue some wood!
Spread glue on the mitered corners (both sides) and started folding the whole thing together as the tape was keeping the joints aligned and tight. I added the horizontal divider before closing the last corner, and the vertical divider, and glued the last mitered corner only to realize (better now then 1/2 hour later) that the vertical divider was put backwards (with the drawer slide facing the back of the carcass). Now it’s funny how quickly the glue actually starts to set as it was almost impossible to pull that divider out – and it’s only held in a 1/8” deep dado and it’s plywood so not a lot of long grain to long grain going on here, but I managed that as well. aaah, that was a close one.
I added some clamps mostly to keep proper pressure and to keep the joints even (I used it to push the top and bottom inwards a little) and to pull the dividers in properly:
And left it as as is for the night
As I mentioned in the previous post, I did route a 1/8” groove on the fronts/back of all the carcass parts to later align the face frames to it. the cut was done to allow for a spline to fit in, but didn’t care much to make a perfect clean cut as it will be covered later. this is purely functional cut/groove:
And this is the victim…. the Incra 1000SE handle bolt. the plastic handle was completely shattered and this bent bold that keeps the miter gauge locked is all that is left:
I was thinking about machining a new one as a one piece aluminum handle+threaded end but am not sure Aluminum would be good enough for this so I may just try to straighten this bold and glue a handle to it – any suggestions (just trying to be creative here as opposed to just ordering a replacement part more than anything)?
Next I’ll probably do the face frames since I may not have enough material for all the drawers at the moment. we’ll see what the mood will strike with next.
Thanks for reading,
-- ㊍ When in doubt - There is no doubt - Go the safer route.