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Cabinets & Drawers: Shaker Cupboard: Rejuvenated Drawer Slips Roy Underhill's Nail Cabinet
Cabinets & Drawers: Shaker Cupboard: Rejuvenated Drawer Slips Roy Underhill's Nail Cabinet
Cabinets & Drawers: Shaker Cupboard: Rejuvenated Drawer Slips Roy Underhill's Nail Cabinet
DRAWERS
From the editors of Popular Woodworking
popularwoodworking.com
1-800-683-8170 leevalley.com
8
CABINETS & DRAWERS 1
INSPIRATION FROM
THE ORIGINAL
The original Shaker stepback, with its
missing crown moulding and other absent
features, required detective work before
construction began. As we move through
the project, we’ll examine some missing
features and try to reach conclusions that
bring this piece back to an earlier day.
The first question is: What about feet?
The cupboard at White Water has a
three-sided frame that rests on the floor.
Was that the original design? Or were the
feet worn away or removed?
Also, what happened to the crown
moulding? It’s obvious there was a
moulding, but it is long since gone. What
was the profile?
Other features to look at are the
unique drawer construction and the use
of a half-dovetail sliding joint to secure
the shelves to the case sides—even with
this complex but strong joint, the builder
nailed in the shelves.
P O P U L ARWO O D WOR K IN G .COM LEAD PHOTO BY AL PARISH; STEP PHOTOS BY THE AUTHOR; LEAD PHOTOS BY ROBERT W. LANG
2
a centered tenon. An edge shoulder of a sections have half-blind dovetailed cor- JIG UP THE SLIDE
matching size ensures a stout joint. ners and shelves attached with half-dove- Now it’s time to cut the mating shape on
There are two frame joints where the tailed sliding joints. the horizontal shelves. To hoist these large
matching edge shoulder is not used: on On the upper section the case top is dove- panels onto your router table is quite a task.
the bottom rail of the lower section where tailed to the sides; on the lower section, the But with a simple shop-made jig, you won’t
the tenon would end up 3⁄8" wide, and on case bottom has the dovetails. The pins of need to. Instead of taking the panel to the
the bottom rail of the upper section where the half-blind dovetails are positioned in router, you’ll take the router to the work.
the tenon would be 5⁄8" in width. the sides with the tails in the mating pieces. Build a jig to create the sliding half-
As always, cut your mortises first then Also, there is a 3⁄4" difference in widths be- dove-tail with two straight pieces of 21⁄2"
cut your tenons to fit the mortises. Set tween the upper case sides and the top, and wide and 3⁄4"-thick scrap that are 24" long.
up and cut all the mortises on your face- the lower case sides and the bottom. Those Screw the pieces together to form a “T”
frame parts. It’s best to cut the mortise offsets capture the backboards. with one leg of the top piece set at 7⁄8".
then reverse the position of the workpiece The half-dovetail sliding joint is easy For the jig to work, you’ll have to size
and make a second pass at each mortise. with two router setups. You can work with that top leg according to your router set-
Yes, the resulting mortise may be wider a single router, but you’ll need to change up. This time use a 3⁄4" outside-diameter
than 1⁄4", but the joint will be centered on the bits multiple times or position the fence template guide bushing with the same
the stock, and that’s most important. in the exact same location each time. dovetail router bit. (The matching diam-
Cut your tenons using your favorite The setups are this: One router has a eters allow the router bit to cut where the
method, then test-fit all your joints. When 3⁄4"-diameter, 14°-dovetail bit coupled with bushing rubs.) Clamp the jig on a test
your tenons fit snug and can be slid to- a 51⁄64" outside-diameter template guide piece, then make a pass to create the half-
gether with a little muscle, it’s time to as- bushing. The second router has a 5⁄8"-diam- dovetail profile as shown below.
semble the face frames. Work methodically eter pattern bit with a top-mount bearing. Check the test piece in a socket. If the
through the assembly. Apply glue to both Begin by marking lines across the sides test piece is too wide, take a light table
the mortises and the tenons to achieve the at both the top and bottom edges of the saw cut off the working edge of the jig,
most strength. Clamp the frames and allow dados. Position and clamp a 3⁄4" fence at make another test cut and check the fit.
the glue to dry. the top edge of a shelf location. Always Continue to take light passes off the jig
work with the fence set to the left of the to sneak up on the correct fit.
FREAKY DOVETAIL JOINTS area to be routed. If these guidelines aren’t If your test piece is too narrow to fill
Dovetails abound in the carcases. Both followed, you can form the half-dovetail the half-dovetailed slot, you’ll have to
P O P U L A RWOOD WO R K ING.COM
CABINETS & DRAWERS 3
BUILD THE BOXES AND PEG upper frame & cabinet detail
THE FRAMES
Assemble the boxes by swabbing glue in
the sockets (and a small amount on the
shelf ends), then slide the pieces together.
After the shelves are installed, butter
the dovetail pins with glue, then tap those
joints together.
When the glue is dry, fit the face
frames to their boxes. It’s important to
align the middle rail of the lower section
with the drawer support. A thin bead of
glue secures the frame to the boxes. Posi-
tion the frames, add clamps then allow
the glue to dry.
Drive square pegs into the face frames.
Doing this after the glue sets provides lower face frame & cabinet detail
additional strength so there is less of a
chance to split the frame pieces. To match
the original cupboard, evenly space four
pegs in each rail and outside stile.
Before adding the pegs, trim the stiles
to the case with a flush-trim router bit
with a bottom-mount bearing. The up-
permost stile’s peg is located behind the
cove moulding. As is done on the original
cupboard, don’t forget to drive a couple
nails into the shelves. 4 5
The detail work on the upper section
face-frame stiles is router work. To cre-
ate the design, make a plywood pattern The door’s flat panels fit into a 3⁄8" deep x White Water cupboard. The drawers use
of the curve — the pattern keeps the 1⁄4" wide groove in the rails and stiles. Plow typical 18th-century construction meth-
look consistent from side to side — then the grooves through the entire length of the ods, but the drawer backs are different—
make the cut using a router with a pat- stiles. (Doing so requires haunched tenons the backs are square at the top and bottom
tern bit. Square the inside corner with to fill in the small lengths of groove beyond and are held a 1⁄4" below the top edge of
a chisel. the edge of the mortise. The haunches are the drawer sides. At first glance, this looks
formed with the dado stack as well.) odd, but there is a nice benefit to it.
THROUGH‒TENON DOORS
Fit each joint so the tenon fit is snug, The cupboard drawers are flush fitting
Construction of the four doors is identical,
but doesn’t require a mallet to assemble. with minimal gaps between the drawer
so after you mill the parts to size, gather
Dry-assemble the frames, then measure fronts and the case. If you build with tight
your stiles and mark them for 1⁄4"-thick
the openings for the panels. Measure across
tenons with 1⁄2" edge shoulders.
the opening, then add 5⁄8" (this builds in 1⁄8"
With through-mortises, work from both 7. You could complete the face frame stile
of space for panel movement). Mill the four
edges of your stile as you mortise so you detail before the frame is attached to the box,
panels to size. Finish-sand the panels and but there’s added stability afterward. Here,
don’t blow out the exit edge. Transfer your
knock off the sharp inside edges around the a plywood pattern ensures a perfect match.
layout lines to both edges of the stiles and
panel area before assembling the doors.
make sure you work within those confines. 8. The door mortises are best accomplished
When ready, add a thin layer of glue to
Work past the halfway point of each by working down from both edges of the
the tenons and in the mortises, then slip stiles. And be sure to keep the slot centered
mortise, then flip the stile edge for edge
the joints together. Add clamps (keep clear for the best results.
to clear the mortise.
of the through-tenons) and let the glue dry.
Most 10" table saws have a maximum 9. Because this dado cut is not a through cut,
Chances are you’ll have small top-to-
31⁄8" depth of cut. The door stiles on it’s OK to use your fence as a stop when using
bottom gaps in the tenon fit. If so, cut thin
this piece are 31⁄4" in width. Because the the miter gauge, too.
wedges milled to the same width as your
through-mortise joinery on the doors ex- 10. I usually grab my Shinto rasp to fine-tune
mortise to fill them. This cleans up the
ceeds the maximum cut, it’s best to install my tenon fit, but with the amount of work left
look. Fit and hang your doors.
your dado stack and sharpen your shoul- to do, I found a bullnose plane did the work
der plane or bullnose plane. that much more quickly.
A DRAWER BUILD – D’OH!
Set a dado stack to its widest cut, raise 11. With #120-grit sandpaper, knock off the
I can’t count the number of antique draw-
the blade to just less than 5⁄16", position sharp edges around the panel area. This
ers I’ve studied, or the number of drawers
your fence to create a 31⁄4"-long tenon, area is difficult to sand after the panels are in
I’ve built. I don’t think I have ever seen
then make the passes needed to clean place, and the softened edges help age the
drawers built as they are on the original
away the waste. cupboard’s appearance.
7 8 9
10 11
P O P U L A RWOOD WO R K ING.COM
CABINETS & DRAWERS 5
Shaker Cupboard
NO. ITEM DIMENSIONS (INCHES) COMMENTS
T W L
BASE
❏ 2 Sides 7/8 18 34 1/4
❏ 1 Bottom 7/8 17 1/4 48 3/8 Dovetailed to sides
❏ 2 Shelves 7/8 17 1/4 48 3/4 Sliding dovetail ends
❏ 1 Top 7/8 20 503/4
❏ 1 Base frame front 5/8 3 7/8 49 5/8 Miter both ends
❏ 2 Base frame ends 5/8 3 7/8 19 1/8 Miter one end
12 ❏ 6 Drawer guides 5/8 11/2 17
❏ 1 Back 1/2 48 3/8 34 1/4 Tongue-and-groove
❏ 6 Profiled feet 3/4 5 1/2 7 1/4
❏ 2 Rear feet* 3/4 5 5
BASE FACE FRAME
❏ 2 Stiles 7/8 3 7/8 34 1/4
❏ 1 Top rail 7/8 1 5/8 43 7/8 11/4 " TBE**
❏ 1 Middle rail 7/8 13/4 43 7/8 11/4 " TBE
❏ 1 Bottom rail 7/8 1 43 7/8 11/4 " TBE
❏ 1 Vertical divider 7/8 4 7/8 27 3/8 1" TBE
❏ 2 Drawer dividers 7/8 11/2 7 1/8 11/4 " TBE
BASE DOOR PARTS
❏ 4 Stiles 7/8 3 1/4 25 1/4
13 ❏ 2 Top rails
❏ 2 Bottom rails
7/8 3 1/4 18 1/4 Through-tenons
7/8 3 1/2 18 1/4 Through-tenons
❏ 2 Panels 1/4 12 3/8 19 1/8
BASE DRAWER BOXES
❏ 2 Outside fronts 7/8 13 3/4 17
❏ 1 Center front 7/8 10 5/8 17
TOP
❏ 2 Sides 7/8 9 1/8 44 1/2
❏ 1 Top 7/8 8 3/8 47 3/8 Dovetailed to sides
❏ 3 Shelves 7/8 8 3/8 47 3/8 Sliding dovetail ends
❏ 1 Back 1/2 47 3/8 44 1/2 Tongue-and-groove
❏ 1 Crown front 3/4 3 55
❏ 1 Crown end 3/4 3 24
14 TOP FACE FRAME
❏ 2 Stiles 7/8 3 7/8 44 1/2
❏ 1 Top rail 7/8 5 1/2 42 7/8 11/4 " TBE
❏ 1 Bottom rail 7/8 11/4 42 7/8 11/4 " TBE
❏ 1 Vertical divider 7/8 4 1/8 33 7/8 1" TBE
TOP DOOR PARTS
❏ 4 Stiles 7/8 3 1/4 31 7/8
❏ 4 Rails 7/8 3 1/4 18 1/8 Through-tenons
❏ 2 Panels 1/4 12 1/4 26
*All pieces are poplar with the exception of the back rear feet which are oak.
**TBE = tenon both ends
15
12. Achieving a tight top-to-bottom fit of your tenons takes time and wastes time. The
holding power of the joint is the flat-grain connection—and that’s not found on the edge
shoulders. A small wedge can tighten up the appearance.
13. Drawer construction for the cupboard is in typical 18th-century fashion, but the drawer
backs are below the sides by a 1⁄4”. Is this a boon or bust?
14. Small profiled pieces of wood hold the drawer guides from side-to-side movement while
glue at the guide fronts and a few brads keep things tight to the dust board.
15. If you flip the position of your miter gauge in the slot, you can guide one half of the foot
pairing for its 45º-bevel cut. It’s similar to using a panel-cutting sled.
16. Make two passes with your blade set at 45º to form the slots for the splines. Add a fence
16 extension and use a push stick to guide your foot through the blade.
P O P U L A RWOOD WO R K ING.COM
CABINETS & DRAWERS 7
Drawer Slips
and could be easily replaced. The whole
arrangement appeared awkward, how-
ever, and was sufficiently unsound that
further experiments were warranted.
A breakthrough came in the 1720s.
An historical detail adds refinement Rabbets were cut into the lower, interior
to projects both period and modern. edges of the sides and front, allowing
both the drawer bottom and runner to
BY GEREMY COY be tucked neatly within the confines of
the drawer. It was a remarkable achieve-
ment in construction. The bottom and
runners were stabilized within the
rabbets, the runners were still easily
replaceable, and, with a nod to appear-
ance, the entire assembly was now hid-
den from view.
One weakness remained, however:
the bottom was fixed in place, unable
to shrink and swell with the seasons.
Though rabbets-and-runners remained
the dominant form of attaching drawer
bottoms through decades worth of cy-
clical expansion and contraction, the
inevitable splitting of bottom boards
called for more ingenious ways forward.
main to support the bottom; 3⁄16" above of the slip on both faces of the board. Saw flush with the top surface of the slips—
and below the groove is a good compro- just outside the line, and plane the result- a look that appeals to more modern
mise between strength and appearance. ing slip down to its finished width. sensibilities. In order to achieve this,
Secure the board, square the upper Prepare the slip to meet the drawer front the sides of the drawer bottom must
edge and plow a 3⁄16"-deep groove a hair and back. First, cut a small tenon at the be rabbeted along their top edges, and
more than 3⁄16" from the reference face. front end. Mark a shoulder line 1⁄4" from the lower, front edge of the bottom rab-
This slight addition will allow the slip to the end, and saw away the material above beted to fit a groove plowed higher up
project from the drawer side so that it and below the groove. The resulting tenon the drawer front.
may be planed perfectly flush after gluing. is a positive version of the groove’s nega- After plowing a 3⁄16"-wide x 1⁄4"-deep
Plane the upper, interior edge of the tive space and should register neatly with groove in each slip, cut a tenon on one
future slip into a series of long facets, the drawer front. Next, form a notch at end. This time, square across the bot-
blending them with light passes to arrive the top rear of the slip. Its depth is equal to tom face of the slip 1⁄4" from the front
at a final rounded shape. Referencing the amount of material above the groove, end, and transfer the mark up the verti-
from the grooved edge, scribe the width which allows the top of the groove and the cal faces to the top of the groove. Saw
bottom of the drawer back to align. out this lower portion, then repeat for
6. Round slips are notched to pass under the Butt the shoulder of the slip’s tenon the other slip.
drawer back and align their grooves with the against the back of the drawer front and Because flush slips simply butt
back’s bottom edge. scribe where the rear of the slip meets against the underside of the drawer
7. Affixing a slip to protrude slightly below the the inside and outside of the drawer back. back, they don’t require a notch at rear.
drawer side allows you to plane it perfectly Transfer the latter mark around the entire Seat the tenons into the groove in the
flush after gluing. slip, and cut and plane it to length. Use drawer front, mark and cut the slips to
8. The groove in the drawer front accepts a the inside mark to square across the top of length, and glue them to the drawer sides.
flush slip’s tenon and eventually, the rabbeted the slip, then transfer it down both verti- Now make the rabbeted drawer bot-
front edge of the drawer bottom. The bottom’s cal faces to the top of the groove. Saw and tom. First, cut a rabbet into the top of
rabbeted sides slide into grooves in the slip. pare away the waste above the groove. one side. The rabbet’s depth should be
9. With the slip firmly seated against the drawer All that remains is to glue the slips in the distance from the top of the slip to
front, mark its finished length directly from the place, clamping to ensure solid contact the top of the slip’s groove and its width
back of the drawer. along their entire length. identical to the depth of the grooves.
10. Flush slips require a specially shaped bot- Next, cut a rabbet into the lower front
tom; it is first rabbeted along the top of one MODERN STYLING edge of the drawer bottom. Its width is
side, flipped over, then rabbeted again along Flush slips are so named because the again equal to the depth of the grooves,
the front edge. top surface of the drawer bottom sits but this time its depth should be the
6 7
8 9 10
P O P U L A RWOOD WO R K ING.COM
CABINETS & DRAWERS 11
12
11 13
14 15 16
11. To ensure a clean fit, the shoulder of the edge of the second side’s rabbet. Cut the with the bottom of the drawer back. Cut
first side rabbet is pressed against a slip while rabbet into the top edge of the second side the notches accordingly, profile the top
the second rabbet’s shoulder is scribed directly to the appropriate depth. edges to match the front slip, and glue
from the other slip. The bottom should now slide in from the side slips to the drawer.
12. Flush slips support a drawer bottom along the rear, its top surface butting against
its sides, while a groove in the drawer front the bottom edge of the drawer back, its WORTH THE EFFORT
receives the bottom’s rabbeted front edge. sides engaging with the grooved slips Slips do require a bit of extra effort, but
13. A view of the back of a drawer reveals the and its leading edge ultimately entering as symbols of attentive and thought-
profile of a flush slip and a rabbeted bottom. the groove in the drawer front. ful work, they imbue meaning even to
14. To simplify the fitting of the mitered slips, parts normally hidden from view. They
glue the front slip in place before mitering and ANOTHER ANGLE evoke, too, the spirit of cabinet-makers
notching the side ones. Mitered slips are perhaps the easiest past who, through decades of experi-
15. A small scrap of wood planed to perfectly version to make. Because they do not re- mentation, wrestled with the intangible
fit the grooves of mitered slips guarantees that quire a groove in the drawer front, they forces of weight and wear and the sea-
they’ll be aligned after glue up. involve much less initial planning and sonal expansion of wood to produce a
16. A drawer front, drawer side and two make laying out symmetrical dovetails tradition of small boxes capable of great
mitered slips combine to form a seemingly a straightforward affair. endurance and subtle beauty.
complex joint. Start by preparing a grooved slip for Given the vast scale of industry and
the front of the drawer. Miter both ends manufacture governing our era, it is now
distance from the bottom of the slips’ to fi t snugly between the drawer sides, rare for those devoted to the intimacy
grooves to the bottom of the groove in profile the top edge to your liking, and of craft to effect such widely influential
the drawer front. glue the slip in place. Next, miter one change. But for those of us engaged in
Set the drawer box on top of the partial- end of each side slip, press it against the making fine things out of wood, quiet
ly rabbeted bottom, pressing the shoulder corresponding miter at the front, and moments of pride at having done the
of the side rabbet against its correspond- mark for length and notching. As in simple things well and beautifully—slip-
ing slip. Scribe a line where the bottom their rounded brethren, the top of the ping drawer bottoms, for instance—often
meets the other slip; this establishes the groove in mitered slips should align prove satisfaction enough. PW
P O P U L ARWO O D WOR K IN G .COM
12
One of the enduring features of Roy sale in Washington, D.C. As I measured are shiplapped.
Underhill’s “The Woodwright’s Shop” the piece, I was bemused by its unusual The assembled carcase is covered with
PBS television show is the familiar and construction—it was a finger-jointed car- narrow 1x battens to make the “crate” easy
rambling back-drop of former projects, case covered in nailed-on battens. to grab and lift. These battens conceal the
parts, tools and wood that frames most Then Roy showed me the reason for joinery on the corners of the carcase.
episodes. My favorite item in his shop is the odd construction: The cabinet was Once you have your “crate” built, you
his nail cabinet— a pine wall-hung cabi- built from an old crate for Ohio Blue Tip can turn it into a cabinet. The interior is
net tucked in the far back corner. Matches made by the Ohio Match Co. of divided into 21 spaces using thin pieces
On the inside of the door of the cabi- Wadsworth, Ohio (1895-1987). For me, of pine that are joined with an egg-crate
net, Roy has hung a print of a lovely lady this made the project even more fun: I had joint. The drawers are simply glued and
holding a bock beer alongside an admir- to first build a crate and then turn it into nailed together; the only thing difficult
ing goat. And while that’s some nice lens a wall cabinet. about the drawers is that you have to build
candy for the television cameras, I’m more As a result, some of the construction 21 of them.
attracted to the 21 drawers on the right techniques might seem a bit odd. If you Finally, the entire cabinet is fronted by
side of the cabinet. These drawers are don’t like them, feel free to change them. a door with mitered corners. The panel
more useful to the married woodworker. My goal was to make a respectable repro- of the original door was simply nailed to
Nail cabinets show up frequently in duction of this charming cabinet because the inside of the mitered door frame. The
traditional workshops of many trades, I’ve always liked the one on Roy’s show. panel had cracked over time, so I chose
and they are illustrated and discussed to make my panel float in grooves plowed
in books about traditional shops. These CONSTRUCTION OVERVIEW into the rails and stiles.
cabinets stored the screws, nails and The original is made entirely of pine— The whole thing is finished with shellac
bolts that a workshop might need. And probably Eastern white pine — though and hung on the wall with a French cleat.
because these fasteners were valuable, any dry softwood will do. The carcase of
many of the cabinets would have a lock. the original crate is joined at the corners THE WALLS OF THE CRATE
The last time I visited Roy, I asked per- with finger joints (though I opted for As mentioned above, the walls of the orig-
mission to measure and reproduce his nail dovetails on my version). The back of the inal crate were joined at the corners by
cabinet, which he purchased during a yard carcase is nailed-on 3⁄8"-thick boards that narrow finger joints (you can see the joints
P O P U L A RWOOD WO R K ING.COM PHOTOS BY THE AUTHOR; ILLUSTRATIONS BY ROBERT W. LANG FROM THE AUTHOR’S MODEL.
CABINETS & DRAWERS 13
5 6
from the inside where they have separated If you can’t get the case perfectly square nal nail cabinet were obviously built up
a bit). I don’t have the jigs or desire to make at glue-up, you have one more chance to using miscellaneous scraps that were
narrow finger joints here, and cutting this pull it square with the backboards. The nailed and glued on to get the job done.
machine joint by hand is just silly. backboards are 3⁄8"-thick boards of pine Some parts were rough-sawn; some were
So I joined the case sides, top and bot- that are shiplapped on their long edges different species.
tom using through-dovetails. The join- and nailed to the back of the case. Instead of replicating every odd scrap
ery is all covered by battens in the end, I used 3d cut fine finish standard nails in the cabinet, I simplified the construc-
so the end result looks the same as the to affix the back, though 4d will do. tion while still maintaining its look and
original. For strength, I put the tails on If your case is out of square, pull the function. On the original, the horizontal
the case sides; the pins are on the top and case square with a clamp diagonally and vertical dividers are joined with egg-
bottom bits. across two corners, then nail the back- crate joints, and so I used that same joint
Glue up the carcase, paying close at- boards in place. This usually helps if the for my dividers.
tention to keeping the corners square at case isn’t too racked. The dividers are all 3⁄8" thick and 6"
both the front and rear of the case. I use wide. Every divider has 3⁄8"-wide slots cut
hide glue for joints like this because it’s THE INTERIOR DIVIDERS into it. The slots on the horizontal divid-
reversible. The interior drawer dividers of the origi- ers are 27⁄8" long. The slots on the vertical
dividers are 3" long. When the dividers Use 4d headless brads to secure the the door. If the hinge leaf is wider than
are knocked together, they will be offset horizontal dividers to the carcase. 1⁄2" you have to shift the battens forward
by 1⁄8" at the front, just like the original. There’s no need to nail the vertical di- a little on the case so the hinge can open
Lay out the locations of all the slots viders to the carcase; gravity and fric- and close.
using the drawings as a guide. I used tion are sufficient. All the battens are attached with
dividers to step off the drawer sizes, brads and glue.
and I used an actual piece of the drawer MAKING IT A CRATE
divider to lay out the width of the slots. The fun part of this project is taking this MITERED DOOR
Note that the three bottom drawers are nice carcase and turning it into a pack- With all the battens attached, you can
taller than the others. ing crate. You do this by nailing on 1x determine the final sizes of your rails
I cut the slots on a table saw, though battens so they look a bit like rails and and stiles for the frame-and-panel door.
they are easy to cut by hand or on a band stiles. There is no other joinery between The corners of this light-duty door are
saw. After cutting the slots, knock the the battens —just glue and nails. joined by miters that are glued and
dividers together and pin the joints by Cut the battens to the sizes shown in nailed, just like the original.
toenailing them with headless brads. the cutlist. The easy way to install these When I cut miters, I saw them first
With the dividers together, knock is to first attach them to the carcase sides, then trim them to a perfect length and a
the assembly into the carcase. The front trim the pieces flush to the top and bot- perfect 45° with a miter shooting board
edge of the horizontal dividers should tom of the case then finish up the work and a handplane.
be located 11⁄2" from the front edge of the on the top and bottom. Even if you love your chop saw, I en-
carcase. That spacing allows room for the The important thing to remember is courage you to give this a try some-time.
bin pulls and knobs on the drawers. that the battens should extend out 1⁄2" I’ve found no easier way to cut perfect
The next step is to nail the horizontal (or a tad more) from the front lip of the miters. By shooting the miters with a
dividers to the carcase. This is done easi- carcase. This 1⁄2" lip creates the opening handplane you can control the length of
ly with a simple jig that makes it (almost) for the door. Before you attach the bat- your rails and stiles in .001" increments.
impossible to miss with your nails. (See tens, make sure their position works And you can hit dead-on 45° with ease.
the photo above for details on the jig.) with the hinges you have purchased for Once the miters are cut, plow a 3⁄16"-
exploded view
P O P U L A RWOOD WO R K ING.COM
CABINETS & DRAWERS 15
7 8 9
Nail Cabinet
NO. ITEM DIMENSIONS (INCHES)
T W L
wide x 3⁄16"-deep groove on the inside and drive a single nail through the stile are captured by the sides. The bottom is
edge of the rails and stiles. The 3⁄8"-thick and into the rail. then nailed on.
panel fits into the groove thanks to a I repeat this process for each corner The drawers look a little odd — the
rabbet cut on all four edges of the panel. (don’t forget to slide the panel into the end grain of the sides and bottom is vis-
Be sure to size the panel so it has a little frame before adding the last piece). ible on the drawer front. But they are ac-
room for expansion and contraction in Then I clamp up the joints using four ceptable for a piece of shop furniture —
its width. ordinary bar clamps. The nails prevent and the drawers in the original have
I don’t own any fancy clamps for the miters from sliding as you apply survived many years of use.
gluing mitered corners —most band pressure at the corners. Begin by fitting all the drawer parts
clamps are fairly frustrating to use — so for each opening. I try to do as much fit-
I glue up miters, corner by corner. 21 DRAWERS ting as I can before assembly. This usu-
First I spread a little glue on the two Because this is a cabinet for nails, it’s ap- ally means the drawer will require little
mating surfaces of the miter and let them propriate that the drawers are nailed to- or no tweaking after assembly. First I fit
dry for a minute. Then I add more glue to gether. All the drawers are construct-ed each bottom to its opening. Then I fit the
the joint. I press the two pieces together in a simple manner: The front and back sides, front and bottom. Then I begin as-
PHOTOS BY VERN JOHNSON
P O P U L ARWO O D WOR K IN G .COM
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11. A single nail through the stile and into the sembling the drawer. catalog; the card could tell you what type
rail prevents things from sliding around as you To do so, place the front and sides in of fastener is inside the drawer.
clamp up this mitered joint. This was, by the position on the bottom. Feel if the draw- To solve the problem, Roy simply
way, how the original door was assembled. er front needs to be reduced in length so wrote what is in each drawer on the bin
12. Get each bottom board to slide in and out the sides are flush to the bottom. If you pull. I think he did it with pencil —it’s
of its opening before sizing the other drawer need to trim the drawer front, trim the almost impossible to see on camera.
parts. If the bottom binds, the assembled back by the same amount. Another thought: Add 2" of depth to
drawer will bind. Glue and nail the sides to the front. the cabinet and you can hang hammers,
13. Dry-assemble the drawer to feel if the Then glue and nail the back to the sides. screwdrivers and other accoutrements of
drawer front is too long. Finally, glue and nail the bottom to the fastening and unfastening on the inside
14. Because the parts are all softwood, which
drawer. Fit each drawer to its opening, of the door.
doesn’t move much once it’s dry, you can numbering the drawer and its opening Install the hinges and knob on the
get away with both gluing and nailing this as you go. door. I used a magnetic catch to hold the
cross-grain joint. door shut. Because I’m the only person
HARDWARE & FINISH who works in my shop, there’s no need
15. If the drawer front is too long, shoot it
As on the original, I used bin pulls for for a lock.
to perfect length with a plane on a shooting
board. Count your strokes. Then reduce the larger drawers and knobs for the I finished the nail cabinet with two
the length of the drawer back by the same smaller drawers in the center. To ensure coats of garnet shellac, sanding between
number of strokes, provided your original I got the bin pulls located correctly, I the coats. The cabinet hangs on my shop
lengths were the same. made a quick drilling jig that I clamped wall with a French cleat made from
16. When I have to do something 14 times,
to each drawer front. The jig ensured I 1⁄2"-thick material.
you can bet I’m going to make a jig to ensure didn’t make a layout error. And now comes the fun part: Empty-
my mind doesn’t wander and cause me to The knobs are located dead center in ing my tackle boxes of nails and screws
make a fatal error at this stage of the project. the fronts of the smaller drawers. and putting them into their new draw-
This simple jig locates the holes for the bin Were I to make changes to this cabinet, ers, which are located conveniently
pulls in the correct place. For the taller draw- it would be with the hardware. While I above my workbench. Oh, and I guess
ers on the bottom, I set the jig 3 ⁄8" lower on like the bin pulls, it would be more help- I’ll have to look for a picture of a lady
the drawer front. ful to have pulls like an old library card and a goat. PW
P O P U L A RWOOD WO R K ING.COM
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Perfect Fit
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