How to Build Cabinets with Cushions or Shelves

Building the Doors Step 1

Cut 16 rails (M) and 16 stiles (N) to the lengths listed in Materials Needed chart. Make these cuts using a stop block screwed to the bottom of a circular saw crosscutting jig, a stop block on a power mitersaw, or the miter gauge extension with stop block.

Step 2

Lap joints connect rails and stiles. Cut these with a backsaw with one exception: In these half lap joints both pieces will be cut. So, set your combination square to 3/8 inch -- half the thickness of the rails and stiles -- to scribe the lap depth on each piece.

Step 3

Apply glue to the lap joints and clamp the joints together to form each door frame. Use spring clamps in pairs at each joint or a single C-clamp at each joint. Use a framing square to make sure the door frames are perfectly square before the glue dries.

Step 4

When the glue has dried, unclamp the frames. Put a 1/2-inch piloted rabbeting bit in your router and set the depth to 5/16 inch. To make the rabbets for the door panels, rout clockwise around the inside edge of the backside of each door frame.

Step 5

The router will leave rounded corners. Square these up with a sharp chisel. Chop down at each side of the corner with the flat side of the chisel against the side of the rabbet. Put the flat of the chisel in the bottom of the rabbet to slice off the waste.

Step 6

Put glue in the bottom of a door rabbet and set a door panel in place. Use a flat-bladed screwdriver or a small putty knife to push glazer's points into the side of the rabbets. Repeat for all the door panels.

Lap Joints: Step 1

Set your circular saw blade to cut 3/8 inch deep. Make a test cut in scrap to make sure the depth is exactly right. Draw a cut line at 1-1/2 inches from the ends of the stiles and rails. Cut along the line, guiding the saw with an angle square.

Lap Joints: Step 2

Starting at the outside edge, make repeated passes over the waste area of the joint until all the material is removed. You don't need to mark or guide these cuts. Clean the bottom of the joint with a sharp chisel.

C-Clamps

If you use C-clamps to glue up the face-frame lap joints, use pads of 1/4-inch plywood or other scrap between the clamps and both surfaces of the wood. This will prevent damage to the workpieces and also helps to spread the clamping pressure.

Continued on page 6:  Installing the Doors

 

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