Pennsylvania Spice Box for Mom #4: Creating the interior assembly

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Blog entry by SPHinTampa posted 04-14-2012 11:46 PM 2785 reads 1 time favorited 0 comments Add to Favorites Watch
« Part 3: Assembling the case and making the feet Part 4 of Pennsylvania Spice Box for Mom series Part 5: Finishing external details on case »

In this session, I was able to:

- Glue the wood fronts onto the plywood shelf stock
- Fit the upper shelf that creates the first hidden compartment
- Route the stopped dado slots for the shelf assembly
- Route the notches for stopped dados
- Create the shelf assembly
- Glued and fit the shelf assembly into the case

When I resawed the curly maple for the drawer front, I was able to use the left over side as my shelf stock.

I planed the left over 1/4” strips to an even thickness 15/64” (approx)

I then cut 2” wide strips on the table saw

And glued the strips to the front of the oversized 1/4” plywood shelves I cut earlier.

I use a rub (or butt) joint to glue these and painters tape to clamp.

As you can see I had a lot of shelves to do.

Unlike the other shelves, the top shelf is constructed of 1/2” stock. Once it was glued, I used the plane to smooth out the joint on this shelf and all the others.

As you can see from the back view, the upper shelf is 1/2 ” ply with a rabbited dado joint.

The rabbited dado joint will be hidden the upper moulding, which creates a false top in the interior and the upper secret compartment.

Using the actual case dimensions (I measure with a mm ruler because it is easier to remember the numbers). I cross cut to size on the radial arm saw.

I mark out the start and stop marks on the router table surface (they wipe away when you are done if you have a laminate router top). Chuck up an undersized plywood cutter (15/64”).

I then route the stopped grooves into the shelving.

Again, use the actual measurements to trim the vertical pieces.

Because I have used stopped dados for the shelves, I route small notches on the shelf sides.

I then dry fit the assembly. The final assembly, due the fact that you have separate, false compartment in the center, requires that you finish the assembly outside the case once you start glue up.

I then assemble the complete shelf unit.

And insert the unit to the case.

Next session, moulding and feet.

-- Shawn, I ask in order to learn

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