|Project by Tom||posted 01-25-2012 01:47 AM||1175 views||3 times favorited||5 comments|
My neighbor was looking at my shop the other day (actually a few months ago) and wondered if I could build some shelves to put his TV and Stereo gear on. He had just mounted his flat-screen on the wall. Using Google Sketch-up, I came up with a design for a cabinet after measuring all of his components. I told them it would take at least a couple of weeks to make it. Two months later I delivered the cabinet—luckily they said they weren’t in a hurry! Good thing! This was my first attempt at any kind of a furniture project. I built it out of birch-faced plywood and poplar, both obtained at the local Home Depot. The overall size of the cabinet is 54” x 18” x 33”. I used 1/2” plywood to build six boxes which I placed on a 2×4 frame. Then I faced each box with poplar. Each of the two bottom openings and the tall opening have adjustable shelves. Again, it was my first attempt at setting up to drill the holes so they lined up. I made my own jig to drill the holes out of a left over piece of pegboard. Now I know why they charge so much for those jigs from Rockler and Woodcraft! I will get one of those next time!! I read in an issue of Wood Magazine about using dark brown Rit Fabric Dye as a base before staining birch and poplar to avoid blotching. I had always used a coat of thinned varnish as a base before, but my neighbors wanted a darker finish. I used minwax English Chestnut stain. I brushed on the dye, then wiped it off and let it dry overnight. Then I wiped on two coats of the stain to get the darker shade. I used a light coat of varnish then I used Minwax wipe on clear satin poly for the final three coats, sanding lightly between coats. The cabinet top is a piece of 3/4” birch faced plywood, again trimmed with poplar. I had planned to use edge banding, but wasn’t sure how it would handle the staining so ended up using 1 1/2” poplar. I learned a lot from this project—one of which was not to be too optomistic in estimating the completion date! I wish I had taken more photos, too. Thanks for looking.
-- Tom in Spring Branch