How to Make a Box-Like Cabinet
- 1). Set the table saw miter gauge at 45 degrees and miter all eight ends of the alder lumber, 24 inches long point to long point of miter.
- 2). Lay the four pieces on a flat surface and spread glue on the mitered edges. Wrap the frame with the strap clamp and tighten till glue oozes out. Hammer one corrugated nail into each mitered joint. Let the frame dry for one hour. Take off the clamps.
- 3). Put the 1/4 inch dado blade on the table saw, slide the fence over to 1/32 inch from the blade and raise the blade height to 1/2 inch. Run all four pieces of the 16-inch plywood through laying flat, creating a 1/4-by-1/2 inch dado.
- 4). Put the regular saw blade back on the saw and tilt the blade to 45 degrees. Miter all the ends of the 16-inch plywood.
- 5). Stand the four pieces up on their edges, dado side down. Smear glue on all the mitered edges. Bring the four mitered edges together creating a frame. Wrap the frame with two nylon strap clamps and tighten. Shoot 1 1/4 inch pin nails into the mitered edges. Let the glue dry for one hour. Take off the clamps.
- 6). Flip the frame upside down and run a bead of glue along the inside corner of the dado. Drop in the 1/4 inch piece of plywood. Nail on the 1/4 inch plywood with 3/4-inch pin nails.
- 7). Flip the box over and run a bead of glue along the edge. Place the 24-by-24 inch face frame on the box on the glued edge flushing all corners and edges. Nail the face frame on the box. Let the glue dry for one hour. Hand sand the cabinet.
- 8). Set the saw blade tilt to 30 degrees. Run the 21-1/2 inch piece of plywood through on all four edges. Sand the edges thoroughly, creating a blunt edge.
- 9). Install the two 30-degree reverse bevel hinges on the 21-1/2 inch plywood door using the screws and instructions that come with the hinges.
- 10
Lay the door on the cabinet, center it, and screw the door to the face frame of the cabinet through the hinges.