As I have mentioned in an earlier post, it was decided early on that we would make the bottom shelf slatted instead of flat plywood. This actually turned out to be a little more challenging that I had hoped. It ended up with 12 slats, originally 14 but I dropped the 2 outer slats because I felt the joinery would be too busy, all connected with dominos to the front and rear rails. I also went ahead and pre-finished this shelf in anticipation of access issues while spraying.
This piece didn’t seem to be working out with the lye treatment and I was fearful that all my hard work was ruined but as it turns out, a coat of lacquer soothed all my worries.
I had to go over to the clients place again to confirm a few measurements and I noticed that they had removed their medicine cabinet. It was only 9 in wide, so I mentioned to them that they should just open up the rest of the space and I could create a new medicine cabinet that would match the new vanity. They agreed and I got to work on it. The medicine cabinet took very little effort, I just took some of the cherry ply scraps and crafted the interior using a piece of birch ply for the back. I used some of the cherry cutoffs for a frame, drilled some shelf pin holes, applied the lye and lacquer and viola!
I cut some glass shelves from some scraps and the cabinet portion was complete.
Up next was the door. I didn’t have enough cherry ply for the panel so I decided to re-saw solid stock for the panel. I found out the hard way that edge gluing 1/4” material is no picnic, but I managed to get through it. After one failed glueup I was able to get it done and the panel came out far better than I could have imagined. I had to apply lye to the panel separately so as not to have lye pooling in the corners. I wanted to apply lye to the frame separately as well but I was unsure wether the lye would affect the glue bond or not.
As I was finishing the door frame, I did end up with some pooling of the lye even though I taped the panel. Again I feared that I had ruined another part but once again a coat of lacquer saved the day.
Now back to the vanity, with all the interior pieces finished it was time to assemble. This was a very tricky assembly there was a lot of room for things to go wrong. But I did get it all together and square.
Drawers, finish, and the big reveal.
-- "One often meets his destiny on the road he takes to avoid it." Master Oogway