Shaker Single-Drawer Cupboard. Part 4.
The door stiles (P) and rails (Q) can now be cut to length and width. When cutting the stiles, it’s best to allow at least an extra inch on each end. After the mortises are cut, this extra length can be trimmed off. Use a router with a 3/4 in. piloted round-over bit to cut the bead on all rails and stiles. Note that the cutter depth should be set to establish a 1/16 in. step as shown.
Next, use the table saw to cut the ‘3/4 in. wide by 3/4 in. deep groove that accepts the panel (R).
The ten m on each end of parts Q can be cut on the table saw using a dado head cutter, although repeated passes with a regular saw blade will also work. A 1/4 in. diameter drill bit can be used to remove most of the waste stock. Use the bit to bore a series of holes, then clean up the remaining material with a hand chisel. Once the mortises are cut the stiles can be trimmed on each end to their exact length.
At this point, if you try to assemble a rail and stile, you’ll note that they can’t
close tightly until a 45 degree cutout is made on each piece. Use a sharp chisel here, and work carefully as this must be a tight joint to look good. Remove only a little material at a time.
The two panels (R) are made next. Begin by cutting each one to length and width from 3/4 in. thick stock. In order to cut the raised panels on the table saw it wili be necessary to make a plywood insert (the opening in a standard insert is too big). Set the saw blade to make a 10 degree cut, then lower the blade below the table. Trace the outline of your present insert on a scrap piece of plywood — 1/4 in. thick for a Sears 10 in. saw, 1/2 in. thick for a Delta Unisaw. With a band or saber saw, cut out the pattern slightly oversized, then sand to fit snugly in the opening. Make sure the plywood is flush with the top of the table saw. Now, using a push stick to hold down the insert, start the saw and raise the saw blade very slowly Continue raising the blade until it is 1 3/4 in. above the table. The rip fence can now be adjusted so that the blade will cut a 1/16 in. shoulder as shown. With the panel held firmly against the rip fence, run the panel through the blade on all four sides.
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