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Cut
the drawer bottoms (K) to size
from 1/4" birch or maple plywood...or hardboard (Masonite),
if preferred. Test assemble all drawer pieces, disassemble,
glue, clamp, check for squareness, wipe off any excess glue
with a damp cloth and set aside to dry.
Once
the assembled drawer box and drawers have dried completely,
carefully sand all assemblies smooth and flush with a belt
sander, then finish sand them with fine sandpaper. Be sure
to remove any sharp edges or corners that could injure children.
Rout
a 1/4" deep by 3/8" wide rabbet around the inside back of
the frame to accept the chalkboard. Square the corners with
a chisel.
The
Chalkboard
Ready-made chalkboards are available through office supply
and specialty stores, or, if you prefer, you can make your
own by spraying tempered hardboard (Masonite) with a special
chalkboard paint that's available at craft stores.
Assembly
Attach the completed drawer box assembly to the frame assembly
with #8 x 1-1/4" wood screws. Drill pilot holes in the chalkboard
and frame assembly to accept #6 x 5/8" wood screws but do
not attach them at this time. Cut and glue the runners (L)
to the bottoms of the drawers.
These thin, 1/32" x 1/2" x 4-1/2" strips will make the drawers
slide easier and give you an equally spaced gap around all
drawers.
If you like, you can add the decorative apple and "ABC" appliques
that are cut on your scroll saw from 1/4" plywood or Masonite.
Paint them with a high gloss enamel, then use the same enamel
to paint the matching drawer pulls.
Finish
the entire chalkboard project (not the actual chalkboard)
with a coat of semi-gloss polyurethane. Mount the chalkboard
into the frame, attach the appliques and insert the drawer
pulls.
List
of Materials
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