Sequence of Operations to Build a Custom Sideboard Using Dowelmax
1/ Create design and sketch of sideboard with ogee feet. |
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| Prepare work piece for Ogee shape feet - Block 1-1/4" x 4" x 15" with 45 degree mitered ends - 4 of. |
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| Use shop made accessory to configure Dowelmax reference block and angle bracket to join mitered ends of ogee feet workpieces. |
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| Position and align Dowelmax miter joint configuration with shop made accessory to drill 4 accurately placed dowel holes. |
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| Dowels are positioned away from the outer edge by use of the 3/8 spacer. |
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| Use table saw to shape outer curvature of ogee feet. |
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| Use hand plane to refine outer shape of ogee feet. |
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| Mark inner curvature of ogee feet using template and shape in the bandsaw. |
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| Glue and clamp feet. |
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| Prepare four corner posts: 1-5/8" x 1-5/8" x 31-1/8". |
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| The two front posts have mating inner verticals: 1" x 1" 31-1/8". The inner vertical has a relief or offset of 1/4" from the face of the front post. The dowel placement is staggered to avoid fouling. Use guides 1, 2 and 3 on Dowelmax to join inner vertical to rail. Then use guides 4 & 5 to join front post to inner vertical. Front post lengths are identical, therefore reference the lower joint from the bottom of the post using the same layout. Use the distance gauge to reference the middle dowels for the post to inner vertical, and for the lower inner vertical to rail dowels. |
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Prepare front and rear rails. Front rails: Two of 7/8" x 2-/18 x 55" and one of 7/8" x 1-1/2" x 55". Rear rails: Two of 7/8" x 2-1/8" x 57" and one of 7/8" x 1-1/2 x 57". Ensure all lengths are identical and all edges are square. |
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| Reference from the top three equidistant dowels in 2-1/8" rail and two equidistant dowels in 1-1/2" rail. |
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| Prepare front and rear inner verticals for drawer assembly: Four of 7/8" x 1-1/2" x 27". Prepare horizontal drawer rails: Two of 7/8" x 1-1/2" x 18". Drawer face heights : Three along top - 4-1/4"; Three at lower center - 6". |
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| All joints are dowel construction with the exception of the joints at the junction of the inner verticals and intermediate rail. |
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| The half lap joints where the inner verticals meet the intermediate rail. |
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| Route rails, stiles and panels for transverse end panels. Stub tenon is 3/8 penetration and requires additional strength. Use shop made stop arrangement to cut stiles to identical lengths and then reference Dowelmax from the top and the bottom to install two dowels at each corner. A spacer is required to center on the stub tenon and collar depths are required to be adjusted to accomodate the tenon length and mortise depth. |
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Work piece sizes for two end panels: Stile: 4 of 7/8" x 3-1/4" x 31-1/8" Rail: 4 of 7/8" x 3-1/4" x 9" Panel: 2 of 7/8" x 9" x 25-1/4" Finished Assembly: 14-3/4" x 31-1/8" |
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| Center panel is 9" wide so 2 - 4-1/2" panels are joined at center line using 6 dowels and the distance gauge. |
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| Route door rails, stiles and center panels identical as for end panels. Again use 2 - 1/4 " dowels in each corner, and 6 - 3/8 dowels to join the two center panel work pieces to widen the center panel as shown above. Each door consists of: Stiles: 7/8" x 3" x 21" Rails: 7/8" x 3" x 11-3/4" Panel: 7/8" x 11-3/4" x 15-3/4" |
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| Drawers: Cut front, rear and side panels for all six drawers using baltic birch or oak faced plywood. Top Centre Drawer(One): 1/2" x 4-1/8" x 17" - 2 of, and 1/2" x 4-1/8" x 14-1/2" - 2 of; Left and Right Top Drawers(Two) : 1/2" x 4-1/8" x 16" - 2 of, and 1/2 x 4-1/8" x 14-1/2" - 2 of; Lower Mid Drawers(Three) 1/2" x 5-3/4" x 17" - 2 of and 1/2" x 5-3/4" x 14-1/2" - 2 of. Butt join drawer front and rear to inside of drawers sides so that no raw edge is visible when drawers are open. Rabbet lower insides of panels to accept drawer bottom to eliminate raw edge. |
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| Use Dowelmax 1/8 spacer fastened to reference bracket by supplied capscrews to center 1/4 inch dowels on 1/2" plywood. Use 4 x 1/4" dowels on smaller drawers. When using 1-1/2" long dowels, adjust drill collar to drill bores 1-1/8" deep to compensate for shorter bores on face joint for drawer sides. |
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| Use 5 x 1/4 inch dowels on larger drawer using supplied index pin to extend the dowels along the end of the drawer fronts. When using 1-1/2" long dowels, adjust drill collar to drill bores 1-1/8" deep to compensate for shorter bores on face joint for drawer sides. |
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| Change the Dowelmax to the second configuration to drill dowel bores into the drawer side faces. For face joint, adjust collar stop to shorten drilling depth to 3/8" deep to avoid drilling through drawer side. |
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| With Dowelmax in the second configuration, use 5 x 1/4 inch dowels on larger drawer using supplied index pin to extend the dowels along the end of the drawer fronts. For face joint, adjust collar stop to shorten drilling depth to 3/8" deep to avoid drilling through drawer side. |
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| Sideboard assembled and dry fitted using no glue and 50% of dowels only. |
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| Sideboard ready for final sanding. |
