FINAL ASSEMBLY

We still need to cut some pieces of wood. The two front edges are 3/4" X 2" X 38 1/8".
Cut two notches in the front of the bottom the same as the drawer dividers.
Dado a 3/8" wide by 3/16" deep notch down the inside back of each side. This will provide relief for the back.
Using a 3/8" Forstner bit drill holes 3/8" deep and 3/8" in from the front edge of each front piece. Place one at the top, one inline with each drawer divider and one at the bottom.

Drill and countersink holes for #6 screws in each hole.

Either purchase 3/8" plugs or make your own using this handy tapered plug maker.

Hex Shank Tapered Plug Cutters

Making a Plug

Align the front pieces with the sides and glue and screw into place.
Using the same process drill three countersunk holes along the top and bottom of each side. Glue and screw the bottom and top frame onto the sides. Make sure that everything is square by measuring from corner to corner. The dimension should be exactly the same.
Use the drawers to properly space the drawer spacers. I allowed between 1/32" and 1/16" for the top of each drawer. Start with the top drawer and work your way down.
Cut (6) pieces 1/2" X 1/2" X 10" to support the spacers.
When you get the spacers where you want them draw a line along the bottom. Align the small piece of wood with the line, glue and nail into place.

Repeat this step for each spacer.
Cut the guide rail 1/2" X 3/4" X 16 1/4".
Temporarily place the spacers into the cabinet.
Drill a countersunk hole 1 1/2" back from the front and 1" from the back for a #6 screw.
Using the drawers align the rails. The rails will be used to stop the drawer so mark it make the drawer stop flush with the front of the cabinet.
Glue and screw the rails to the spacers.

Place the spacers into the cabinet and glue the spacers to the sides, front and the supports. Clamp and let everything set good.
Glue the taper plugs in all the holes with the taper plugs we made earlier.
After they are dry cut them flush with a flush cut saw.

Dozuki Dovetail/Flush-Cut Saw

Sand everything smooth and apply the finish. I used an environmentally friendly, water based stain and polyacrylic finish. It was the first time I used it and it turned out great. I especially liked the water clean up!

EF High Performance Polyurethane Top Coat

I first applied two coats of Golden Oak stain within 30 minutes of each other. After 24 hours I applied a heavy coat of Black Cherry and made sure I stroked it in the direction of the grain.
After 24 hours I started applying the polyacrylic finish. Apply a coat, let dry for 24 hours, bronze wool rub and repeat at least three times. I did a very light 600 grit sand before the final coat.
Cut the back from 3/16" plywood to fit the dadoed area in back. Nail into place with small brads.

That's it! Now fill it up with DVD's and enjoy a movie.

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