I wrote a long note yesterday with several pictures, but when I went to post it an error page came up. Not sure what happened, but I’ll try and summarize.
I decided I should glue-up the cabinets before making the face frames. Normally I would just oversize the face frame a little and plane it flush to the case. But I can’t do that as the top overhangs the sides. Then there is the side bead on the stiles. By gluing up the cabinets first I can scribe the face frames to them, then plane to fit before forming the side bead.
I disassembled the dry-fit cabinets and made a punch list of things required before assembly. This included planing a side bead on the back edge of the sides (Gene’s doesn’t have this), dadoing the sides and top for the backs, cutting the shelves to final width, etc. I also decided to wedge the tenons. I used a plunge router for the dados (I hate that thing!).
Glue-up: first came the top and sides (through tenons), then the shelves were set in place (these will be pegged later) and last the dovetailed bottom. Once everything was together, I went to work on wedging the tenons.
My practice wedge went together great. I cut the kerfs 1/8” from each end and made the wedges with a chisel. However, the glue had started to gel, and the wedges took more force and most of them snapped before doing any real “wedging”. I’m sure this will be fine (what other choice do I have?) as some of the wedges do press the tenon outward, and all but the front tenons will be covered with the upper cabinet. I was physically and mentally shot after the glue-up and quit for the day. On a positive note everything went together nice and square.
Some additional comments: I molded the lower cabinet’s top by cutting a 1/8” x 3/8” fillet with my Stanley 78, then used a block plane, a gouge and a scraper to finish it. I will probably hit it with sandpaper before finishing. I used pegs on the unsupported ends of the bottom. I made these with a dowel plate. I figured the bottom should have pegs because of the direction of the dovetails.
Pictures: Molded top, Side bead and dado, Making pegs, Practise wedge, Glue-up
Next will be the upper cabinet assembly. Remember to reply!