Great Idea or Just Madness...

[Matanuska]

Thanks for the pictures - now I understand what you have in mind.

[tfrayne]

I am currently building the drawers. Each of the three cabinets will have four drawers. Two at 4.25" on top, a 6" in the middle, and a 10" on the bottom. The drawers are each about 14" deep except one of the 6" drawers will be extra deep to store lathe chisels.

While I am trying to do most of this project on my Mk V, my box joint jig will only work on my other table saw.

I built all of the smaller 4.25" drawers first. Tonight I started on the first of the three 10" drawers. Herein I found my error.

As best I can figure, I do not have quite enough of a tight fit on my spacing for each notch cut. It did not show itself on the smaller drawers other than a slightly tight fit. However, on the larger drawers, the error shows itself readily. Fortunately I only did one drawer, so I can fix this with only having to recut that one drawer. I will have to run a longer test cut to ensure I have corrected my error before moving on.

Box joints are simple and tedious; a recipe for errors and accidents. I am moving slowly on this part and if I have time in the evening, I only do one. At my slow and methodical pace, each drawer takes about 30-40 minutes to cut.

I already nearly ruined one of the smaller drawers. I was all set up to make a cut and realized I had positioned it wrong in the jig.

The last time I did box joints on plywood I had a good deal of blowout. To remedy that on this project, I am using scrap pieces behind each workpiece.