|Project by jmartel||posted 08-09-2015 11:38 PM||2240 views||2 times favorited||20 comments|
A good friend of mine saw the walnut coffee and end tables that I built for myself and asked me if I could make him an entertainment center that he was considering buying from Pottery Barn cheaper. Deciding that I needed to replace my old craftsman tablesaw and that he’s helped me enough to justify doing some work at a discount, I accepted. Plus, this way instead of MDF, they received cabinets out of much sturdier plywood. After some brainstorming with him and his wife, we came up with the idea to use a craftsman style instead of the style of the pottery barn cabinets:
My changes in the trim are:
I had only done plywood casework once before, and it didn’t go that well, but I figured I had a couple more years experience now so it would work out.
So after getting a check I drove north to Bellingham to pick up a Grizzly tablesaw and a grizzly tracksaw to make things easier. After picking up about $1300 worth of materials, I started to break down the sheets into more manageable sections:
Cut all the dado and rabbet joinery using my router and edge guide, and everything went together quite smoothly. I used a slot bit to create slots on all of the forward faces to attach the solid trim. I ended up having to get couplers to extend my pipe clamps since I didn’t have any clamps long enough for the 62” wide center pieces.
Once I got the cabinets mostly together and edged, I built the doors. There aren’t really many photos of that process, but they make a big difference once they are put in. Unfortunately my cases weren’t quite square when glued up, which made fitting the doors a big hassle since they are inset.
Rather than a simple molding, we decided on curved dentil blocks. More work, but I think it really sets this apart from what you can buy commercially. This was my first time cove cutting on the tablesaw, but it went quite smoothly. Just a pain in the butt when sanding/finishing. Next time I’ll finish the blocks separate and nail them on later after finishing everything else. I mistakenly glued them on the trim before finishing.
Blurry photos from when I first delivered the cabinets about a month ago. Schedules didn’t line up very well, so I couldn’t do the finishing touches until today:
All in all, a big project. I’d definitely charge more for anyone else since I definitely gave them a really low price, but I don’t regret it. Got a lot of experience and I still had enough money after materials to buy a tablesaw, tracksaw, and a few other things.
We finished off today’s final touches by watching a MotoGP race.
-- The quality of one's woodworking is directly related to the amount of flannel worn.