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Creating the Built in Cabinets and Doors

Bob meets with Ryley to discuss the site-built, built-in cabinets of �� Birch plywood. The cabinets were all precut in the shop before being transported to the location. Back at the shop, Ryley shows Bob many of the cuts and jigs used in the crafting of the cabinets. Then shows Bob some of the techniques used to make the panel doors using a router, table saw and radial arm saw with a dado blade. They create mortise and tenon joints to hold the frames of the panels.
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Creating the Built in Cabinets and Doors

  computer-generated transcript - may not be 100% accurate

" Now these cabinets are gonna be installed right into the wall. How are you building them?"

" Well, we're building them out of this 3 quarter inch birch plywood-- "

" -Yes."

" -And we have a hall at the house this was how there was just big hall that's 10ft 9 12" inches."

" That's the wall in the den?"

" Yes"

" That's how big the den is?"

" That's right."

" And so, what we're gonna do is build 3 separate base cabinets at 42 12 inches and then 3 a upper cabinets will sit on top of the counter [unk]"

" So, the upper sections which will have book shelves are actually separate from the bases."

" That's right."

" Good. And 42 inches, that's a nice width. Of course 48 inches is about far as you could go coz plywood comes in 48 inch widths , but this makes for a 21, 21 12 inch door?"

" Yes a 21" inch door."

" Which is nice size. That way it doesn't bump in to the furniture and it looks right."

" Alright."

" So, you've got one almost complete. One under way, what are you up to next?"

" Well we're ready to build the 3rd box right here and we've got a sheet of plywood if you wanna give me a hand--."

" -Sure--"

" -working on this"

" - beautiful stuff."

" Okay. So, now we'll cut the sides of the cabinets at 19 and a quarter inches."

" And the height of the cabinet is what?"

" 28 12"

" And we make those cuts on that. See normally, you take a minor gauge which is an accessory to the saw and you use that to guide your board, do your work through the blade and get a nice square cut. But with a piece of wood this is sizeable as this, 19 by 8ft, you need something else."

" That's right. That's, that's it's probably the first auxiliary piece you'll make for the saw,--"

" - accessory."

" Yes accessory."

" There's this jig for cutting these pieces just like that--"

" -Yes, and it's just--"

" -and it just goes to the next groove slides back and forth with the fence at a 90 degree angle to the blade."

" 1/2 inch plywood and a hard wood edge all the angles are 90deg. So, your work use is gonna be perpendicular? You got measure what say 20?"

" 2812.--"

" -Alright, 2812 like that."

" Okay. Now were gonna deal with joining the side pieces to the back. We're deal, were working with 3 quarter inch stock, Right?"

" That's right and what we're using is a dado blade"

" -Yes. --that has been set to a plow out 3 quarters of an inch and were going to plow it 3/8 deep, which is half a distance of the stock and that's where we'll put the back"

" So the corners are .unk"

" The side pieces are just butted together to the bottom piece nailed and glued, and then we've cut a notch to create a toe kick for your foot[unk] and get into. . Now were ready to put the back piece on."

" Okay. And we'll just put some glue in this area here we'll plow it out.--"

" -Yes."

" -and the back will go right on there and we'll nail it into place with some fully painted finish nails."

" We could have made flesh plywood doors, but instead were crafting paneled doors and we've created a more [unk] joint here for the styles and rails and were using quarter inch plywood. What was the first step here Riley?"

" First thing we did was create this detail right here on both the styles and rails which you call the parting bead"

" Yes. and we did that with the router mounted on this router table."

" Yes, which is a real neat accessory to have"

" -It's great--"

" -you take a regular router and you just have mounted it upside down unto this router table."

" Right. This is a, the bit were using here and well going to be sure always to push the material into the cutting blade."

" Yes."

" The next step is to plow out a quarter inch rabbit it to receive the panels. we'll cut all of the styles and rails for length."

" Okay Riley, how do you cut the tenon unk?"

" Well for this we're gonna use the radial arm saw [unk] Bob, and as you can see we're gonna be putting it off centered because we don't wanna be getting too close to this parting bead detail here."

" Yes."

" Were going to a, take it off of the face first and we're gonna do it on two passes because were creating a 1-inch tenon with a 3 quarter inch dado blade. Well having adjusted the blade, were going to make a more shallow cut on the back side,"

" Now in order to create this mortise in the style, [unk] Riley will just plunge it into the table saw, so that we get enough space in there to create a nice joint."

" I have a pencil mocked that's gonna guide me so I don't take out so much material."

" And the last cut is 45 that will get that perfect milder. Okay. So we've put a spot of glue on each of our mortise and tenon joints at the four corners but that's it. No nails and certainly no glue where the styles and rails hold the panel in place coz that could cause splitting in the future. Let it sit for a day and they'll be ready to go in. Thanks, Riley."

" Okay."

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