So far I have covered the basic case construction. Next we need to add the back panel and make the dust frame (or web frame) for the drawer. This will also serve as the installation point for the upper knife hinge.
So, I started by gluing up a 1/4” panel of Sapele for the back, using the router bit as a guide for the final thickness.
Next, we can cut the groove in the case pieces to accept the panel. I am using a 1/4” straight bit and cutting 3/16” deep. We don’t have to worry about stopping the groove, as the mitered corners will hide it. It is critical though that we get a clean cut, so I put a good amount of pressure against the router’s base to prevent the cut from wandering.
Repeat this for all the case parts, and then dry fit the case to check the alignment. Any adjustments can be made with a few shavings from a hand plane.
Now, for the dust frame.
With the parts cut over sized, I want to start with the stopped dado that will house the frame. I know I want the drawer to be 4” deep, so I measure four inches from the dovetail baseline, and make a pencil mark. I also want to stop the cut before the front edge, so I make a mark about 3/8” from the front edge.
I’ll then set down a straight guide (scrap wood block) to guide the router. I need to make a plunge cut here, and stop just shy of the marks made earlier. I’ll also stop shy of cutting through the groove holding the back panel. I’ll then square up the cut with a chisel.
Next, I need to size the parts to fit, and cut a small notch that will extend the front piece past the end of the stopped dado and rest flush with the front of the case.
Then, I’ll glue the parts together with a simple butt joint, and start to prepare the frame and panel door parts.
Part #4 will cover the frame and panel door and hopefully a successful knife hinge install.
Thanks for looking.
-- Matthew, Columbia - South Carolina ----- Jesus was a carpenter...