I have been busy the last couple of weeks and have not had much shop time. Rob come over last night though and we made some progress on the sofa table.
We started with the drawer sides. They need to be 1/2″ thick, so we re-sawed the 3/4″ boards that were set aside for the sides and rears of the drawers, then planed them down the rest of the way.
Rob cut the pieces to length, then cut the vertical grooves in the side pieces.
He then rotated the sides and cut the bottom groove. When the sides were done, Rob cut a small chamfer on the bottom, back corner of the drawers.
He then did a bit of planing to clean up the burn marks on the edges.
After the sides were done, he cut the rabbets on the drawer back pieces.
Bouncing around a bit, we decided to leave the drawer faces till later, and work on cutting out the drawer holes in the front apron.
I laid out the three holes to get an idea how big my routing jig would have to be.
Next, I measured the distance from my router bit to the edge of the base plate of my router. Doubling that dimension and adding it to the hole dimension, I laid out a larger rectangle on a scrap piece of plywood.
I set the fence to match my marks, then raised the table saw blade up through the board, to cut most of the four sides. Then I hand-sawed out the corners, leaving a rectangle in the middle.
Placing the frame over the apron board, I attached some permanent rails to hold it centered over the area to be cut. Leaving one of the rails long allowed me to clamp the new jig into place.
Keeping the router tight to the edge of the jig, Rob ran the router around the frame to cut a rectangular opening. We dropped the bit down 1/4″ at a time until the plate, in the center, was cut out.
We then unclamped the frame and slid it down to the next one and repeated the process.
When we were done, we had three new drawer holes.
Moving back to the drawer faces, we carefully set the blade to do some mildly complicated grooves around the edges. The PDF attached in the first post, of this project, explains the cuts, so I will just show the steps we took.
We did test fits every step of the way, to make sure all the sides would fit tightly together. Loose joints would leave us with drawers that would break easily.
When we were satisfied with the fit, I took a measurement and Rob cut down the plywood for the drawer bottoms.
The last thing we did for the night was round over the drawer faces with a 1/4″ round-over bit.
The drawer joints are nice and tight because the drawers stay together without glue, well enough to test out the fit in the holes in the front apron.
Looks like we are down to clean-up and assembly. The only other piece to cut will be the top.