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In the prior photos (0 Bookcase), though hard to see, I have already prepared the corners of the frame. Specific steps were:

1. Cut selected (i.e., no flaws that will weaken the frame) 8 / 4 poplar to rough length on the miter saw
2. Divide these lengths into about 3 1/2 inches rough width on the band saw – i.e., if your rough plank is 8 ” wide, split it into 2, if 10″, split it into 3
3. Calculate the number of rough pieces needed to make the 4 frame corners – 3 ” X 2 ” approx. – from a single panel.  This will be a total rough width of about 14 inches – including allowance for waste.
4. On the jointer, level the top and botom (widest) rough surfaces of each board – about 70% “clean” is enough to get the edges square
5. Again on the jointer, square both edges of each piece
6. Prepare to laminate the panel by aligning the edges of each squared piece, alternating the end grain orientation (reduces chances of warping) and then glue and clamp firmly – see the photos.  This will create a single rough panel from which each corner piece will be cut to final size. Note: You could skip this step and create each corner from the rough cut lengths, but I find that this approach tends to waste more wood and also tends to produce small inconsistencies in the dimensions. If your corners are all exacttly the same dimensions, it is easier to achieve a perfectly square cabinet.
7. Plane the panel to target thickness – 2″
8. On the table saw, after making sure the fence is properly set for final width – 3 inches – and that the panel edge that will run along the fence is perfectly flat (i.e., no banana), cut the 4 pieces to width
9. Again on the table saw, square one end of each corner piece prior to cutting to final length
10. Set these pieces aside – later the mortises will be cut for the rails.
11. Repeat this process to prepare the 2 side panels and the back panels
12. Similarly, prepare the 4 side frame rails and the single stile for the rear panels

In the photo above the jointed pieces are being positioned and glued prior to being clamped edge to edge.

Above:  The panel pieces are clamped.  Note the pieces are oriented such that the grain direction is alternated from piece to piece, to minimize warping.

Set them aside for about an hour.  Below, clamps removed and now ready to be planed …

Laminated Panel

Planing Bottom Panel

 Final thickness 3/4″ …

Panel at final thickness

 Once the frame is dry-assembled and the actual final dimensions are taken,  the panels can be cut … width first, then length.  I usually leave about 1/4″ of play on the width to allow for seasonal expansion and contraction.

Posted on March 28th, 2010 by Carl
Filed under: Mission Bookcase