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The Complete Illustrated Guide to Furniture & Cabinet Construction

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The Complete Illustrated Guide to Furniture & Cabinet Construction The COMPLETE ILLUSTRATED Guide to Furniture&Cabinet Construction ANDY RAE ➤ Cabinets and Built-Ins ➤ Drawers, Doors, and Shelves ➤ Internal Architecture ➤ Bases, Backs, and Tops ➤ Hardware and Fasteners The COMPLETE ILLUSTRATED Guide to Furniture&Cabinet Construction TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) The COMPLETE ILLUSTRATED Guide to Furniture&Cabinet Construction A NDY R AE t TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) SECTION SEVEN OVERVIEW Text © 2001 by Andy Rae Photographs © 2001 by Andy Rae (except where noted) Illustrations © 2001 by The Taunton Press, Inc. All rights reserved. Pp The Taunton Press, Inc., 63 South Main Street, PO Box 5506, Newtown, CT 06470-5506 e-mail: [email protected] DESIGN: Lori Wendin LAYOU T: Steve Hughes, Suzie Yannes PHOTOGRAPHER: Andy Rae (except where noted) ILLUSTRATOR: Melanie Powell LIBRARY OF CONGRESS CATALOGING-IN-PUBLICATION DATA: Rae, Andy. The complete illustrated guide to furniture & cabinet construction / Andy Rae. p. cm. Includes index. TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) ISBN-13: 978-1-56158-402-4 ISBN-10: 1-56158-402-9 1. Furniture making--Amateurs’ manuals. 2. Cabinetwork--Amateurs’ manuals. I. Title. TT195 .R34 2001 684.1’04--dc21 2001033100 Printed in Thailand 15 14 13 12 11 10 About Your Safety: Working with wood is inherently dangerous. Using hand or power tools improperly or ignoring safety practices can lead to permanent injury or even death. Don’ t try to perform operations you learn about here (or elsewhere) unless you’re certain they are safe for you. If something about an operation doesn’t feel right, don’t do it. Look for another way. We want you to enjoy the craft, so please keep safety foremost in your mind whenever you’re in the shop. To Paul McClure, head chief and happy woodworking hero who bridged all barriers, social to scientific. May we reap the fruit of the wisdom he left behind on his beloved mother, the Earth. Acknowledgments irst, my humble appreciation to my Jim Budlong, and David Welter, for teaching from editors at The Taunton Press. I was lucky afar; William Draper, who gave me the freedom to to have three: Helen Albert, associate pub- explore—and paid me for it; Tim Snyder, whose lisher, whose eagle vision lifted an idea insights always point the way; Mira Nakashima, for Fthat, at the outset, appeared too heavy to fly, and bridging the old and the new; Lonnie Bird, who’s Jennifer Renjilian and Tom Clark, for their support, quiet approach bespeaks fierce skill; Edward Schoen, steadfastness—and swift solutions. for showing me how to problem solve my way out of For excellent photographic services, I credit the anything; Kitty Mace, for challenging everything; Pat folks at Commercial Color in Allentown, Pennsyl- Edwards, for hosting itinerant woodworkers; Ned vania, and at Iris Photography in Asheville, North Brown, who unwittingly inspired me to excel; Simon Carolina. And special thanks to John Hamel, photog- Watts, for being the gent of all gentleman woodworkers; rapher, for short- and long-distance mentoring, plus Steve and Susan Blenk, for persistence and tall good- some pretty fine photos over the years. will; Tom Brown, who patiently taught a young man I’ve had the curious luck to know many fellow the art of installation; Leonard Lee, a bona-fide tool woodworkers and writers on a personal level. My nut and enthusiast; Kevin Ireland, my first editor (you deepest gratitude goes to my woodworking and writ- never forget your first); David Sloan, for curiously ing teachers, past and present, who have knowingly encouraging curiosity; Frank Pollaro, for adventure and unknowingly inspired and taught: My creative and bravado; Mike Dresdner, who’s always there when mother, Johanna Weir, and my two artistic fathers, Jud there’s nowhere else to go; Eric Stang, for enthusiasm Rae and Walter Weir, all three for their unique inter- and artistic inspiration; Paul Anthony, whose feedback est in making things; brother Gurnee Barrett, who keeps my feet on the ground; Janet Lasley, for helping demonstrated it was worth doing right; George me to stay alive in the business of woodworking; Steve Nakashima, for his unspoken commands, Frank “Pimo” Metz and John Yarnall, who both demonstrate Klausz, for his outspoken commands, and Toshio that patience and planning always win the day; Ellis Odate, for speaking the unspoken; Dave Cann and Walentine, for clever solutions and unexpected Paul Connor, whose metalworking hands have saved detours; Mike Callihan, for last-minute woodworking; mine many times; the crazy woodworking folks at the folks at the Lehigh Valley (Pennsylvania) Guild, Arcosanti, including Kerry Gordon, Michael Christ, for their sometimes embarrassing encouragement; Ric and Chris Fraznick; Fred Matlack, who never says it Hanisch, for having the courage to design from the can’t be done; Sue Taylor, for asking elucidative ques- heart; Peter Kauzman, for staying up late; and Manny tions; Dave Sellers, for his anarchy with heart; Jim Pagan and Yeung Chan, both exemplifying what true Cummins, for huge excitement in small things; Rich woodworking passion is all about. Wedler, whose woodworking is music to my ears; Last, I thank my family, Lee, Zy, and Shade— Jonathan Frank, for trusting woodworkers; Palmer especially my wife, Lee Speed—for enduring my “one Sharpless, for his wisdom on woodworking—even in year leave of absence” for writing this book. I love you the dark without electricity; “Old” Jim, Michael Burns, guys and always will. TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) Contents Introduction • 2 How to Use This Book • 3 PART ONE Tools and Materials • 6 ➤ SECTION 1 Shop Necessities • 8 TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) 8 Shop Space and 11 Mobilize Your Fixtures Workshop ➤ SECTION 2 Woodworking Machines and Tools • 13 15 Basic Handheld 16 Favorite Edge 17 Fundamental 18 Sharpening 20 Clamps Power Tools Tools Layout Tools Gear ➤ SECTION 3 Working Wood • 22 23 Buying and 27 Flattening a 28 Smoothing 30 Good Sanding 31 Keeping Preparing Solid Board by Hand with Edge Tools Techniques Parts Flat Wood 33 Plywood and 35 Mixing 36 Laying Out 37 Making 38 Choosing and Other Man- Materials and Cutting Your Mark Using Glue Made Boards Plywood ➤ SECTION 4 Designing Furniture • 40 42 Understanding Wood Movement PART TWO Box and Case Construction • 44 ➤ SECTION 5 Basic Cases • 46 53 Inside 57 Securing Case Parts to a Wall TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) ➤ SECTION 6 Shelves • 58 64 Shelf Joinery 66 Open Shelves 68 Shelf Options 74 Dressing Up a Shelf ➤ SECTION 7 Nails, Screws, and Other Fasteners • 81 TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) 84 Nails and 86 Hardware Screws Solutions ➤ SECTION 8 Assembling Cases • 88 92 Clamping Problems ➤ SECTION 9 Cutting and Attaching Moldings • 95 98 Working with Moldings ➤ SECTION 10 Drawers • 101 110 Drawer 115 Tray 117 Drawer Construction Construction Interiors ➤ SECTION 11 Drawer Hardware • 119 124 Drawer Slides 126 Computer 127 Drawer Pulls Hardware TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) PART THREE Doors • 130 ➤ SECTION 12 Building Doors • 132 136 Doors with 141 Solid Doors 143 Glass Lights Panels ➤ SECTION 13 Fitting and Hinging Doors • 145 TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) 150 Installing 153 Specialty 157 Shopmade 160 Hiding Doors Basic Hinges Hinges Hinges ➤ SECTION 14 Door Pulls and Hardware • 161 165 Pulls and 167 Locks 171 Catches and Handles Bumpers PART FOUR Bases, Feet, and Stands • 176 ➤ SECTION 15 Bases • 178 184 Toekicks 189 Installing Cabinets ➤ SECTION 16 Feet • 197 201 Feet and Casters ➤ SECTION 17 Stands • 206 208 Making Stands TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) PART FIVE Frame Construction • 212 ➤ SECTION 18 Legs and Aprons • 214 220 Strong Joints 223 Aprons 225 Legs and Rails ➤ SECTION 19 Chairs and Stools • 231 TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) 237 Chair Joints 241 Chair Backs 242 Chair Seats 245 Hitting the Floor ➤ SECTION 20 Face Frames • 247 250 Making Face 255 Corner Units Frames xii Grooves, Dados and Rabbet Joints ➤ SECTION 21 Frame and Panel • 256 261 Making 265 Back Panels Strategies PART SIX Tabletops and Work Surfaces • 268 ➤ SECTION 22 Making Tops • 270 276 Top 284 Top Options 288 Leaves Construction and Ends ➤ SECTION 23 Attaching Tops • 292 294 Allowing for 297 Hardware Movement Solutions Sources • 300 Further Reading • 301 Index • 302 TJ52-01-2008 IMUS 7/UOA0068-Furniture&Cabinet ConstructionW:9.25”XH:10.875” 175L 128g White A M/A Magenta(D) Introduction aking furniture is one of your shop space are part and parcel of the the most satisfying ways to craft. By combining all your skills, you can pass time: The schiiick of a make any type of furniture your dreams con- plane iron on wood; the jure up.
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