I am really close to finishing this cabinet. I just had a few details left.
I started with the edge banding on the shelves. I grabbed a 2″ wide piece of oak and planed it down to 1/16″ thicker than my shelves. I set up the male edge banding cutter in the router table and ran the board through on both sides.
I then cut that board in half so I had the two shelf edges that I require. It is usually safer to cut your trim from a wider board, then rip it to size later. The next step was to load the female cutter and cut the receiving slot in my shelves.
I brushed glue evenly into the groove and clamped the trim into place.
When it was dry, I trimmed the wider edge band flush to the face of the shelf.
I also put a 1/8″ round-over bit in and rounded over the edges.
The shelves fit perfectly. The openings for the doors are just barely big enough to angle the shelves in. I did attach the center support with screws just in case they wouldn’t fit, but everything seems to work fine.
The last things to build are the doors. I ripped a 1/4″ wide groove along the inside edge of all of the frame pieces, on the table saw.
Then I cut the tounges on the horizontal pieces to fit that slot.
I cleaned the grooves with a narrow chisel and planed the tounges of the mating pieces to get as close a fit as possible.
The dry-fit looks good, so I moved on to the center panels.
I cut a 3/16″ deep x 1-1/2″ notch around the front of the panels.
Then I cut a 3/16″ x 1/4″ notch on the back.
I cleaned up the notches with my shoulder plane then dry-fit the panels.
They were a bit snug, but went together well. Snug is good because I still had to sand them down to get rid of the burn marks.
Once everything was sanded, I installed spacer foam to keep the panels from rattling, then applied glue to the last 4″ of each side groove.
I reassembled the doors and clamped them up.
I ran into a bit of an ego check when I placed my perfect doors into their homes. Holy crap, they were 2″ too narrow. I went back to my plans and immediately found the problem. The center panels were supposed to be 1′ 2-3/4″ and I made them 12-3/4″. Oh well, I wasn’t fond of that 2″ center support anyway…
I dug through my pile of oak until I found a 6-1/2″ wide piece and quickly milled it down to size and cut a groove for the shelf standard on the back side. After drilling out four pocket holes on each end, I attached the new center support.
Thankfully it looks like it was designed to be there…
With that small crisis averted, I moved onto door hardware. After installing the hinges I noticed that the doors rubbed slightly upon closing. I want them to look tight so I planed a slight back-angle to the side that faces the center support. Now it swings freely but looks tight to the frame.
After the door was hung, I attached the handles and the catches. Even installing the screws by hand and using pilot holes, I still had several screws break. Luckily I could move things around just slightly so the broken screws were not visible.
Finally everything was complete and ready for finish. Since I had so much trouble with the screws, I decided to mask off the hardware that was on the pre-finished areas, to prevent any more problems.
I did have to pull the hardware from the doors to apply urethane though.
Since I won’t have room to spray everything at once, I decided to do a few of the smaller pieces by hand. I laid out the doors and the new center support an applied the first coat. Hopefully the finishing will get done this week and I can make plans for delivery.