DRAWER ASSEMBLY

The first assembly I did was the drawers because I wanted to have my cabinet sized to my drawers instead of the other way around. To adjust the cabinet was a lot easier than trying to adjust any minor dimension changes to the drawers. Since the drawers were a little harder they came first.

NOTE: I discovered after I had completed this project that some of the newer cardboard DVD's are wider than the plastic ones. Because of this the drawers will not close with them standing on edge. Boy I hate it when that happens! The dimensions below are for the plastic ones. If you want it to fit everything I'd suggest measuring every DVD case you can get your hands on and adjust the dimensions appropriately.

For my drawer joints I used blind dove tails on the front and through dove tails on the back. You could use housed rabbit joints but I wanted to use my new Rockler Dovetail Jig.

Rockler Dovetail Jig & Through Dovetail Template

Since it was the first time I use it there was a little learning curve but it worked great!
Here's a little tip for setting it up. I used a pair of dial calipers to exactly set the fence, it worked great.

Using the table saw sled you made from our plans, www.runnerduck.com/tablesaw_sled.htm, cut the drawer fronts 3/4" X 9 1/2" X 6 7/16".

Dado 3/8" off each side 3/8" deep.
Cut the sides 1/2" X 6" X 15 7/8".
Cut the backs 1/2 X 8 3/4 X 6 3/4".
Cut the bottoms 3/16" X 8 1/8" X 15 3/8".
Cut a notch in the center bottom of the back 1 1/2" wide and 3/4" deep.
Cut a 3/16" dado along the bottom of each piece 3/4" up from the bottom. This will be for the plywood bottom. Do not cut all the way to the ends. Stop short and finish the dado with a chisel.

Using the joinery of your choice, set the front, back and sides to join.
Using a 1/4" round over router bit, radius the tops and bottoms of the sides and back.

Notice the vacuum attachment for the router. We made it from the instructions in our September 24, 2004 newsletter.

Sand everything to a finished smooth.
Glue the drawers together using clamps and calls from all sides. Make sure the drawer is square by measuring from corner to corner, the dimensions should be exactly the same.

Cut the guide rail 3/4" X 1 1/2" X 15 1/2". Dado a 13/16" groove 1/2" deep the full length of the rail.
Dado 1/2" off one end of the rail 1/2" deep.

End View

Side View

Glue the rail to the bottom of the drawer. Be sure that it is perfectly parallel to the sides.

Drill the hole for you knob and you are done with the drawer except for the finish.

Now on to the FINAL ASSEMBLY --->
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