In this part I fabricate the front sides top and bottom do a dry fit up and then glue it all together
Fabrication of the front
I did quite a bit of brain squirming trying to figure how I could profile the three laminated parts so they were all the same.
Essentially I gave up and glued the three together into a laminated one piece front.
I lay the parts out on my table saw top so I had a flat surface to work on.
I used the two long ends as datum lines to get everything on one plane and as flat as possible and glued and clamped it.
After letting it dry overnight I then used my Oscillating sander to finish the profile.
As I still had pencil lines from the templates I simply just sanded it down to the lines, inverted it and did the other half.
Now I know its possibly not perfectly symmetrical but its as close as I could get it.
Here is a shot of it dry assembled.
Note: The long wings at the ends have not been cut off yet
Fabrication of the sides and back
The fabrication of the sides and back presented no problems, Joint them, thickness them cut them to length, match them up, biscuit joint them together then them dry and then trim them down to size.
I staggered the sides and the back to keep the joints separated.
Fabrication of the top and base or bottom.
As I said at the beginning I used block board for the lid and bottom.
It was originally 19 mm so I ran it through the thicknesser to get it down to about 15 mm .
Using the raised panel template again I cut out the profile for the top aand bottom.
The lid or top is a flush butt joint.
The bottom or base is a tongue and groove fit.
The bottom actually a raised panel upside down, I cut a reverse panel profile on the edges and then matching slots in the front sides and back.
It took a bit of fiddling at sanding to get it to fit in and satisfy the clearances for movement.
I dry fitted everything together and it all looked good, it matched up OK so it was glue up time.
A lesson was learned here….do not throw off cuts in the bin as you may possibly need them to assist in clamping!
As luck would have it the rubbish PU did not occur early, god knows what the neighbours thought seeing me searching through the bin and pulling out small curved bits of wood!!
-- Regards Robert