Glue and screw the top and bottom panels in, repeat the steps and attach the left and right side members. Remove the clamps, bore the shallow larger hole for the plug, then rebore for the screw body and shank diameters, respectively. Clamp the top and bottom members in place and bore 1⁄16-in. The heads are then concealed with wood plugs. Wood screws and glue are used to attach the side members. Again, check the product first for clean sticking and removal. Since many plywood panels have some degree of warp, it is advisable to use a stronger tape for this gluing operation to ensure against the parts popping apart. Working on a flat work surface, glue them in place. These deeper cuts are made last so a non-tippable wide surface is always on the table.Īfter the glue has set, interlock the panels (they won't need glue), then cut the smaller end panels to length. Then raise the blade and reposition the fence to make the second series of cuts, which will drop out the waste. Make two passes in each block to cut the shallower bottom kerfs first. Here's how it's done on the table saw: Tilt the blade for a 45-degree bevel cut. In fact, a tight fit will cause assembly problems. This tends to loosen the fit of the panels in the notches, but the slight looseness is okay. Otherwise, use a jig saw with a narrow blade and work it across the corner. Repeat the sawing on the eight panels, alternately flipping them over for the second notch cut.Ī quick way to drop out the notch waste is to bore a 1⁄2-in.-dia. ⚠️ Don't automatically shift the block a 1⁄2 inch from the first position, or you will have an error equal to the saw blade thickness. from the first one, measured outside to outside. Do this with the eight panels, then shift the stop block so the second kerf cut will be 1⁄2 in. Cut 6 inches into the panel to make the first cut for a notch, then flip the panel over, end-to-end, and make the first cut for the second notch. Here's how to obtain uniformly spaced cuts: Clamp a stop on the radial-arm fence 12 3⁄8 in. If you don't have a dado head, simply make two kerf cuts with a smooth-cutting, regular saw blade. You can make these notches in one pass on table saw, using a dado head. The diagonal cross panels are assembled with edge half-lap joints: 1⁄2-in.-wide notches are cut halfway through the mating pieces. Test the tape on scrap to make sure yours comes away clean. ⚠️ Some brands of tape leave a sticky residue when removed this type must be avoided. intervals to obtain good contact throughout. Don't skimp with the tape use 6-in.-long strips at 3-in. They are trimmed flush to the panel surfaces with a block plane after the glue has set. You won't need clamps to glue on the strips use masking tape instead to apply the necessary gluing pressure. Start by sawing the panels to size, making sure to allow for the add-on 1⁄8-in, strips. If you can't obtain solid birch in this size, you can substitute maple because it has a fairly similar appearance. The angled joining blocks are cut from 6⁄4 stock. All exposed plywood edges are faced with 1⁄8-inch-thick strips of solid birch. Intended for serious wine buffs, this pair of racks holds about five cases each, for a total storage space of 10 cases, and is built using the modular system.
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