MAKING CABINETS AND BUILT-INS

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Making CABINETS & BUILT-INS

MAKING CABINETS AND BUILT-INS
Make cabinets, built-ins, shelves, and modular units. Covers every step with over 400 photos and drawings, simple plans (and tips on making your own designs). "Everything you ever wanted to know about cabinetry can be found in this vast storehouse of knowledge." -- Country Almanac. "This has it. I recommend this book." -- Int'l Woodworking 368 pages, color illus. Sam Allen—author of The Wood Finisher’s Handbook (“Authoritative…a compelling addition”—Chip Chats), The Wood Joiner’s Handbook (“An excellent choice”—Fine Woodworking) and others—now provides novice woodworkers with the finest guide to creating cabinetry. It takes newcomers by the hand and leads them through every process in detail, from understanding the properties of wood to reading a plan, from layout, squaring, and cutting to joinery and assembly. Allen discusses lumber grades, sizes, and prices; edge treatments for plywood and reconstituted wood products; transferring patterns; and handling all the necessary tools. There’s advice on case and panel construction, designing shelves, drawer hardware, and making freestanding modular cabinets, along with plans for modular built-ins, cabinets for home entertainment, and electronics built-in cabinets.

INTRODUCTION

Tools
Safety

Materials

Wood Properties

Softwoods and Hardwoods · Density ·
Moisture Content. Knots

How Wood Is Cut
Lumber Grades
Hardwood Grades ·Softwood Grades
Surfacing
Lumber Sizes
Standard Sizes · Pricing
Veneers
Plywood
Softwood Plywood Grades ·
Hardwood Plywood Grades
Reconstituted Wood Products
Particle Board · Hardboard ·
Wafer Board · Oriented Strand Board
Edge Treatments for Plywood and
Particle Board
Veneer Tape · Plastic T Moulding ·
Other Methods

Plastic Laminates

Reading Plans

Types of Lines
Visible Lines · Hidden Lines ·
Dimension Lines · Center Lines
Types of Drawings
Multiview Drawings . Pictorial
Drawings
Details
Cutaways · Cross Sections ·
Revolved Sections · Long Breaks ·
Center Lines
Full-Size Patterns
Architectural Drawings
Choosing a Set of Plans
Scaling
Transferring Full-Size Patterns
Transferring Grid Patterns
Bill of Materials

Layout, Squaring, and Cutting

Layout
The Story Stick . Using a Tape
Measure · Making Marks · Using a
Square
Truing and Squaring
Using a Plane · Correcting Defects ·
Surfacing and Squaring Rough
Lumber
Cutting
Using a Crosscut Saw · Using a
Rip Saw · Using Power Saws ·

Making Curved Cuts

Joinery

Joinery Tools
Chisel · Backsaw · Router
The Five Basic Joints
Butt . Rabbet · Dado · Mitre .
Half-Lap
Advanced Joints
Mortise-and- Tenon · Box Joints ·
Dovetails

Assembly Techniques

Glue
Types of Glue · Applying Glue
Clamping
Hand Screws and C-Clamps ·
Bar Clamps
Fasteners
Nails · Screws · Particle
Board Fasteners

Carcasses

Skeleton-Frame Construction
Case Construction
Panel Construction
Face Frames
Tops
Backs
Cornices
Bases and Legs

Shelves

Design Considerations
Fixed Shelves

Adjustable Shelves

Doors

Slab Doors
Panel Doors
Glazed Doors
Cleated Doors
Door Applications
Flush .Overlay Lipped
Door Hardware
Sliding Doors
Tambour Doors

Drawers

Drawer Guides

Built-In Cabinets

Standard Sizes
Built-In Construction
Building In Place · Prebuilding
Installation

Cabinet Construction

Plans
Step-by-Step Directions
Carcass . Drawers · Doors and
Drawer Fronts · Corner Modules ·
Installation · Counter Top·
Appliance Garages
Modular Cabinets--Bills of Materials

APPENDIX: BUILT-IN PLANNER
METRIC EQUIVALENTS CHART
ABOUT THE AUTHOR
INDEX

INDEX

 A
Appliance garage
   corner, 255, 271, 272, 364
   roll top, 256, 272-273, 365
Assembly techniques
   clamping, 147-151
   fasteners, 151-158
   for carcass, 259-261
   glue for, 143-147
 B
Backs, 174-177
Backsaw, 99-100
Band saw, use of, 93-94
Bar clamps, 147-151
Bases, 179-182
Bathroom vanity
  double door, 283-286, 307-309, 331-333
  drawer module, 287, 310-311, 334-335
  single door, 281-282, 305-306, 329-330
Bevel cuts, 168-169
Bill of materials, 72. See also under spec ic cabinet
Board feet, 26
Bolt-and-cross dowel fastener, 157-158
Bookcases, 72, 231
Bowing, correction of, 80-81
Box joints, 140
Brackets, shelf, 192-196
Built-in cabinets, 228-229
  construction, 231-235
  installation, 235-240
  planner for, 366-379
  standard sizes, 230-231
C
Cam fitting, 158
Carcass
  backs, 174-177
  bases and legs, 179-185
  case construction, 161-162
  cornices, 177-179
  directions for, 257-261
  face frames, 169-170
  joint layout, 245
  panel construction, 162-169
  skeleton-frame construction, 159-161
  tops, 170-174
  Case construction, 161-162
  Casein glue, 146
  Catches, door, 208
  C-clamps, 147-149
  Center lines, 63, 66
  Ceramic tile, 238
  Chisel, 96-99
  Chopping, 96-98
  Circular saw: 88-89, 130
  Clamping, 147-151
  Clear-face cuttings, 24
  Construction. See spec i ic types of cabinets
     built-in place, 231-235
     cabinet, 241-243
     case, 161-162
     panel, 162-169
     skeleton-frame, 159-161
  Contact cement, 144-145
  Coped joint, 167, 168
  Coping save: use of, 91-92
  Corner modules, 264-267, 373
    single-door base, 358-359
    single-door overhead long, 360, 362
    single-doar overhead short, 361, 363
    two-door base, 356-357
Cornices, 177-179
Counter tops, 238-240, 270
Crosscut saws, 84-86
Crosscuts, on table saw, 90-91
Cross section, 61-63, 244
Cupping, correction of, 79-80
Curved cuts, making of, 91-94
Cutaways, 59, 61
Cutting, 257
   with crosscut saw, 84-86
   with rip saw: 86-88
   with table saw: 128-129, 131, 168
D
Dado blade, 117, 122-123
Dadoes, making, 258-259
Dado joint, dovetailed, 221-222
Defects, correction of, 79-83
Door(s)
  applications, 202-206
  cleated, 202, 203
     directions for, 262-264
     glazed, 200-202
     hardware, 206-209
     panel, 199-200, 201
     slab, 197-199
     sliding, 209-210
     tambour, 210-214
     under-the-counter, 249
Dovetail, 141-142, 221
Dowel joints, 102-108
Dowels, for reinforcement, 132, 133
Drawer(s), 215-222
    bill of materials, 346-355
    directions for, 261-262
    fronts, directions for, 262-264
    guides, 222-227
    joint layout, 245
    pulls, 227
    under-the-counter, 250
Drawings
    architectural, 63, 66, 67
    isometric, 56, 58, 59
    multiview, 51-56
    perspective, 59
    pictorial, 56-59
Drop ceiling, 238

E
Edge mitre, 125, 126, 130-131
Edges, truing of, 81-83
Edge-to-edge butts, 110-113
Enlarging plans, 71-72
Epoxy glue, 146
Exploded views, 59, 60

F
Face frames, 169-170
Face mitre, 125-129
FAS hardwood, 23
Fasteners, 151-158, 191-192
First and seconds, 23
Flitch, 27
Flush door, 203-204
Flush drawers, 223
Frieze, 179
Front, plans for, 244
G
Glue block, 102
Glues, 95, 143
   applying, 146-147
   types, 144-147
      waterproof, 31
H
Half-lap joints, 134-137
Hardboard, 34
Hardware, door, 206-209
Hardwood
    angles for dovetail, 141
    grades, 23
    minimum sizes for grades, 24
    plywood grades, 29-32

I
I nstallation, directions, 267-270

J
Jig, dowelling, 104
Jig saw, use of, 93
Joinery, 95-101
Jointer, 10, 25, 119, 130
Joints
    box, 140
    butt, 101-110
    dado, 119-125
    dovetail, 141-142
    edge-to-edge butt, 110-113
    half-lap, 134-137
    mitre, 125-134
    mortise-and-tenon, 137-139
    rabbet, 113-119

K
Knock-down fitting, 156-157

L
Layout, 73-77
Legs, 179, 182-185
Lines
    section, 61, 63
    types in plans, 48-51
Lipped doors, 204-206
Lipped drawers, 218-219, 223-224
Locks, door, 208-209
Long breaks, 63, 65
Lumber
    edge-joining using bar clamps, 149
    grades, 22-24
    pricing, 26
    sizes, 25-26
    surfacing, 25

M
Marks, making of, 77
Materials, 9
    bill of, 72. See also under spec ific cabinet
    wood. See Wood
Measurement, 75-77
Metric equivalents, 380
Mitre box, 127-128
Mitre joints
    fitting of, 131-132
    reinforcing of, 132-134
Modular cabinets. See also specf ic cabinets
    construction, 233-235, 241-243
    installation of, 236-237
    plans, 243-256
Mortise-and-tenon joints, 137-139, 166, 167
Moulding, plastic T,40-42
Muntin backs, 176-177

N
Nails, 151-154

O
Oblique projections, 56, 57
Oriented strand board (OSB ) 34
Overhead cabinets, 251
Overhead modules, 372
    corner, 254
    long, 288-292, 312-316, 336-342
    long corner, single-door, 360, 362
    short, 293-297, 317-319, 320-321, 343-345
    short corner, single-door, 361, 363
Overlay doors, 204, 205
Overlay drawers, 219, 223-224
P
Panel adhesive, 145
Panel construction, 162-169
Paring, 98-99
Particle board, 33-34
    edge treatments, 35-43
    fasteners for, 156-158
    load-carrying capacity 187
Patterns, full-size
    plans for, 63
    transferring of, 69-70
Penny system, 151-152
Plain-sawn lumber, 20-22, 111, 112
Plane, 122
    bevel cutting with, 169
    for cutting edge mitres with, 130
    use of, 78-79
Planner, built-in, 366-369
Plans
    choosing, 66-68
    details of, 59-63
    drawings, types in, 51-59
    enlarging of, 71-72
    full-size patterns, 63
    line types in, 48-51
    scaling of, 68-69
    transferring full-size patterns, 69-70
Plastic laminate, 43-47, 239-240
Plywood, 27-32
    edge treatments, 35-43
    load-carrying capacity 187
Polyvinyl acetate glue, 144
Power saws, 88-91. See also spec fic saws
Prebuilding, 232-235

Q
Quarter-sawn lumber, 20-22, 111, 112
R
Rabbets, 257-258
Radial-arm saw, 89, 117, 128
Reinforcing block, 102, 103
Revolved sections, 63, 64
Ripping, 90
Rip saws, 86-88
Router, 10, 100-101
    making rabbets with, 117-119
    use in making dadoes, 123-125
S
Saber saw; use of, 92
Safety, II
Saws. See specific  types ofsaws
Scale, architect's, 68-69
Screen mould, 42
Screws, 147-149, 154-156
Scribing,237-238
Selects, 23
Shaper, 10
Shelves
    adjustable, 190-196
    design considerations, 186-187
    fixed, 187-190
Shooting board, 82-83
Skeleton-frame construction, 159-161
Softwood
    angles for dovetail, 141
    grades, 23
    plywood grades, 28-29
Splines, 108-110, 132-134
Square, use of, 77
Squaring, 77-85
Sticking, decorative, 165, 166, 167
Story stick, 74-75
Stud finding, 235-236
Styles of cabinets, 246-248
Surfacing of rough lumber, 83-85
T
Table sav  89-91
    bevel cuts on, 168
    for cutting mitres, 128-129, 131
    for making box joint, 140
Tambour door, 273
Tape measure, use of, 75-77
T-bevel, sliding, 141-142
3rd clear lumber, 23
Threaded insert, 158
Toe kick, 179-180, 270, 271
Tongue-and-groove backs, 176, 177
Tongue-and-lap locked joint, 220, 221
Tools, 9-11. See also speciific tools for joinery 95-101
Tops, 170-174. See also Counter tops
Transferring
   full-size patterns, 69-70
   grid patterns, 70-72
Truing, 77-85
Twisting, correction of, 81
U
Under-the-counter cabinets
   corner module, 252-253
   double door, 276-278, 300-301, 303, 324-326
   drawer module, 279-280, 302, 304, 327-328
   modular, 371
   single door, 274-275, 298-299, 322-323
V
Veneers, 26-31
Veneer tape, 35-40
Wafer board, 34
Wobbler, 122-123
Wood
   density, 16-17, 18
   figure, 20-21
   grain, 20
   hardwoods, 15-16, 23
   how it is cut, 19-22
   knots, 19
   moisture content, 17, 19
   properties of, 12-14
   softwoods, 14-15, 22, 23-24
Wood products, reconstituted, 32-34

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