I want to rip some
3/4" ply to the widths that I need for each of the benches. I usually do not make
wide cuts at the table saw. The Incra TS-III has two sets of stops. The arrow points to
the one that is closer to the blade. My fence is usually against this stop when using the
table saw. The further stops are for when I use the insert router. Today, I want to use
the further stops for making wider cuts. When I installed the Incra TS-III, I carefully
aligned the fence and set the stops at both positions so that I could use the further
stops for wide cuts as I ma doing now..
I make the cut. Note that I am keeping my eyes on the board and the fence. As
long as I feed the board smoothly and keep the edge against the fence, I will get a good
and safe cut.
I test fit the top.
I have added several finishing touches to these tops. First, I added a 1 1/2" edge on
the front and sides so that I could round them over. I have also added a piano hinge
to each bench top and sanded all the pieces. Now I can move to the second part of Debbie's
project the cabinets.
I am using 3/4" white melamine chipboard for the cabinet cases. I
have ripped all the stock to width, rabbetted the sides to receive the back and am now
cutting all the case parts. There are three cabinets in all.
I am lucky to have an
accurate eight foot fence extension for the miter saw. I have zeroed it for the blade and
can make the many cuts needed with repeatable accuracy.
There are a number of ways that I could have constructed the cases of these cabinets. I am
using pocket hole joinery simply because I can assemble the units faster, and I do not
need to clamp each piece. The pocket holes at the top will not be seen, and the ones on
the bottom will be covered over and painted.
I line up
opposing sides so that I can drill the shelf clip holes to match. I don't want the shelves
to be slanted.
I have used this shelf hole
drilling jig for over a dozen years. I am using a 5mm Vix bit. I simply place the bit in
the hole and drill a precisely depthed hole. The jig is the Rockler JigIt for
shelf drilling.
Along with the pocket
screws, I am using Gorilla Glue. This is the only type adhesive that works well with white
melamine stock. A word of caution: use it very sparingly. The squeeze out can be a bear to
remove and that is putting it mildly. I use lacquer thinner to clean up any
unwanted glue marks and my hands.
I use one
clamp to hold the pieces together.
As I screw each of the
pocket screws, the joint becomes very tight. I am using 1 1/4" washer head screws
with coarse threads. The washer head keeps them from being pulled through the
chipboard. The coarse thread is recommended for this material it get a stronger
grip without splitting the core.
Pictured below is this screw a picture is worth a thousand words. This
screw is perfect for this application. This
is a McFeelys product; click here to go there.