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Forming the Rabbets
Using your table saw with a Combination Blade and a Zero Clearance Table Insert, cut away the small 1/8-inch or so square scrap from the inside edges of all frame stiles and rails to create the 3/8-inch x 1/4-inch glass rabbets (see Section A-A). Take your time and be very careful when making your set-up for this cut, as any error here will affect the fit of all frame members.
Now, locate and drill the holes for the dowels used to hold the corners of the rails and stiles together, then locate and drill the holes for your glass shelf pins. Glue and assemble each frame, taking care to clamp them square, with end and edge surfaces flush. Remember that you cut these to exact size earlier, so you should have no extra stock to sand off, once assembled.
Next, set up and cut the 60-degree bevels on the sides of the frames (see Figure 1). Remember that the back frames are cut at 60-degrees to the face side while the others are cut at 60-degrees to the back side. Now, locate, drill and countersink the screw holes used to assemble both back frames.
Using hardwood veneered plywood, make the cabinet base (K) and shelf (L). As an option, you could glue-up solid hardwood stock to make these pieces. Whichever option you choose, be sure to build them a little oversized. Once the glue has dried, use your jointer to true-up the back edge of each piece so it’s straight and square. Cut the 60-degree angled edges, then rip and joint them to their finished size. Continue . . . |
