Hi on the Woodpecker today, the vanity is comming along pretty nicelly. I managed to glue everything I did
plus I make the doors.
Our new vanity is well underway, but it's far from being finished.
Now, I need to cut both dividers.
And just like for the bottom, I begin by taking care of the edging.
Place the dividers in place, mark their length and cut them.
This will look just like that.
But before going any further, I need to mark the dominoes' placement
and cut the mortises.
I have a bunch to drill;
but before I can glue all this together, I need to make the final sanding on the inside of the plywood.
Now, I can begin gluing this. First, I'll glue the back to the top.
After spreading some glue on the joint, the mortises and the dominoes, I put both pieces together.
I want this to be square, so I add four wooden squares and clamp all this to my workbench.
When the glue is dry, I glue one side, and again,
I spread glue on the joint, mortises and dominoes, so I can put the first side in place.
Next, I add a lot of clamps.
Then, I can do the same thing for the other side.
Before the glue sets, I scrape the excess glue inside the cabinet
and leave it to dry.
When it's dry, I try the bottom and separators in place.
But to keep both separators at the right place while the glue dries, I cut two scrap pieces of plywood to keep them in place.
With those two, the separators will be at the right place.
But to do this, I mark the centre of the cabinet
and the centre of the spacer,
align both marks together and clamp them in place.
I do the same thing for the other side.
Now, I'm able to glue all this together.
I begin by spreading a bit of glue inside the rabbets and on the back frame.
Then, I lay the bottoms in place.
Next, I spread glue on the separators and put them in place.
Finally, I use a lot of clamps.
Since I don't want my spacers to stick to the cabinet, I add some right angle to their other side and remove the spacers.
Next, I temporally add some screws while the glue dries.
After checking that all the clamps are OK, I leave this to dry.
But after removing the clamps the next morning, I notice that the back is not glued to the separators properly.
And because of that, the plywood can move.
I fix this by drilling some holes through the solid maple and into the plywood.
In each hole, I add a dowel and cut the excess.
I put three dowels in each side of each separator.
Next, I start to work on the base.
I begin by ripping some boards to the
right height of the base.
The front and both front sides have a mitred corner so I make the forty-five degree cuts first.
Next, I mark and drill the mortises.
Then, I dry fit those three pieces and mark the back mortises and cut them.
Bur after another dry fit, I notice the centre is a bit too flexible for my taste; I cut a stretcher for the centre.
Now that I'm happy, I disassemble it, spread glue on the joints and clamp the base.
Now, I can finally start to work on the doors.
I begin by ripping all the wood for the rails and stiles.
When I have enough, I cut them to size.
All done.
Now, I can hold the doors in place with clamps and mark where I'll cut the domino's mortises.
And you might have noticed that the one near the centre is farther away from the side than the others.
This is because I need space for the groove I'm going to cut.
After all the marks are done, I cut the mortises.
Since I don't want to goof up again, I mark the groove's placements and cut them.
Before cutting them, I double check if I'm OK.
All the rails are cut right through. But not the stiles.
I begin after the mortice and stop before the next one.
When it's done, I can take the measurement for the inside panels.
And for once, this wood is ready.
And for once, this wood is ready.
I'm going to use this opportunity to hide the glue joint.
So I begin by marking what I need to rip off, from the distance of the glue line.
I do that for all the panels.
Then, I can move my rip fence to each panel line and rip the first side.
Next, I can move the rip fence to the width of the panels and rip them.
I now have all my panels.
I need to make the V grooves.
After cutting all the ones that are near the side, I move the fence up until the bit is in the centre of the glue line and cut the rest of the grooves.
Then, just like for the big side panels, I make a rabbet in the back.
After checking that this will be perfect, I make the final sanding of
all the places that will be difficult to sand after the glue-up.
And finally, I can glue the doors.
Four doors drying.
And while the glue dries, I can begin to work on the moldings.
The first thing I do, is to plane some boards to the thickness of my moldings.
Then, I rout a half round on both edges of each board.
Next I rip the bull-nose.
The last thing to do is to cut a rabbet.
Ok, I should have enough moldings for the job.
Now that the glue on the door is dry, I can cut them to their final dimensions.
First, I put two doors in place and make sure one edge is lined up with the inside divider.
On the other side, it's what I need to remove.
I begin by measuring what I need to remove, divide this in four, mark the doors, and cut both of them.
When I put them in place, it's not perfect, I fix this with a plane.
When I'm happy with them, I do the same thing but for the height of the doors.
When both pair of doors are done, it's time to sand the glue squeeze out.
Now comes the hinges. I begin by marking the centre of the hinges' hole.
When it's done, I drill all the holes on the left.
After each hole, I check if the hinge will fit.
I do this for the four doors.
Then, I move the stop and repeat all this for the right hinges.
When I'm done, I mark the inside of each door.
Since each door is a little bit different, I don't want to mix them up.
But before putting the doors in place, I have to take care of the bottom of the cabinet.
OK, after putting the cabinet like it should be, I can return to the hinges.
I begin by drilling some pilot holes for the hinges' screws.
Then I screw them.
The first screw is a charm. But when I screw the second one...
This couldn't have gone any worse.
Now, I need to remove the broken screw from there.
Using a small chisel, I remove some wood around the screw, so I can take the pliers and remove it.
I take care to keep the hole square. Now, I just have to plug it with a piece of wood.
But since this is the first hinge, I can continue to work on the other side.
But from now on, I'm going to use a normal screwdriver to screw them.
Now, I can install both right doors.
With an open back, this will be so simple.
But the doors have to stay put, so I clamp them in place.
Then, it's as simple as drilling pilot holes and screwing the hinges.
When I'm done, I remove the clamps and adjust the doors.
In no time, I have two functional doors.
I need to do the same thing for the other two.
But before, I need to finish to repair that small hole; which was barely big enough for pliers.
At least this mistake doesn't show at all.
I just need to do the same operations I did on the last two doors.
And after a little while, I have four functional doors.
And the first thing I do, is to remove them and lay the cabinet on its side.
Now, I can sand the rails and stiles to their final grit.
Then, I cut the moldings.
I begin with the first forty five degree cut.
Then, I measure its length directly on the cabinet and cut it.
But those cuts are just in the ballpark, for accurate cuts, I clamp a square on my sander.
And each end is sanded at exactly forty five degrees.
I check the fit, and since it's still too long, I return to the sander.
One done. Three more to go.
When they fit well, I remove them and sand them a little.
Next, I put a little bit of glue and put them in place.
When they're all glued in place, I put as much weight on them as I can.
While the glue dries, I can start the same thing on the doors.
But before cutting the moldings, I remove the weight and scrape off the excess glue, before it has time to settle properly.
Then, I finish the door.
And just like for the cabinet itself, I put as much weight on it as I can.
The next day, I turn the cabinet and do the same thing on the other side.
But now I'm a little scare that when I scrape off the glue, I scratch the wood, so I re-sand again.
Since I have the sander in my hand, I soften the door's edges a little.
Finally the doors are done.
But I'm far from being done.
If you want to see what I do next you'll have to come back to The Woodpecker.
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