If I have more that 2 parts to shape, I will make a template out of mdf. I prefer a nice solid jig made from 3/4” mdf with toggle clamps, however since I only had 4 lower side rails to make I kept it simple. After rough cutting the curve at the bandsaw, I used a 1/4” thick template carpet-taped to my workpiece. A pattern bit mounted in the router table makes quick work of cutting the gentle curves. I try to rout “downhill” on curved pieces. In other words, I start at the center of the workpiece and move towards the end. This means one pass is a climb cut, however I am only removing 1/16” of material so it works fine.
I set up my sanding station, and sanded all the parts for the side panel assemblies. My planer leaves a smooth finish, so I start with 120 grit, and finish with 150 grit. I have found that sanding with finer than 150 grit does not improve the finished product.
Test fitting the frame and panel side assemblies.
I labeled the solid wood panels as I cut them to size for the upper and lower sections. This way the grain pattern continues through the middle rail.
At this point I need to decide whether or not to pre-finish the components before assembly. I rarely pre-finish individual wood pieces, but it is often helpful to pre-finish certain sub-assemblies. Getting the spray gun between the drawer dividers can be a real challenge, so I am leaning toward pre-finishing on this project.
Next up will be sizing the back panels from 1/2” plywood, and dry assembling the front lower rail. Then work can begin on the internal webbing.
-- Willie, Washington "If You Choose Not To Decide, You Still Have Made a Choice" - Rush