Here’s where we apply the edge tape to the doors and front panel assembly. Since you already have some experience at this, it should go quickly.
– Iron on the edge tape to both door edges and the panel edge.
– Remove excess tape by laying flat and sanding with the 100 grit sand paper. DO NOT use 60 grit sand paper. It will scratch the doors/panels.
– While you are edge taping, apply edge tape to the carcass at all points that will be exposed in the final cabinet. This should be obvious at this point. Sand edges with the sander or a sanding block with 100 grit sand paper.
This is the step that allows the beauty to really come out in the doors and panel.
– Watch the video clip on the molding installation. Look at the picture below.
– Take the T5 molding pieces. Practice with a few small pieces on your compound miter saw cutting the inside angles. You should make accurate and fine cuts to “walk in” on your measurement. All 4 pieces in each panel should dry fit tightly together.
– Apply a little glue at the mitered joints and a dab in the center of each piece and let it dry.
– Do this for each panel. You will end up with 9 panels x 4 sides = 36 pieces as you work.
– Referencing the picture, drill and attach the door pulls to the doors.
We need to install the Front Panel Assembly so it can be easily removed from the cabinet so you can get to the inside for service, get access to cables and show off your cabinet to your drooling buddies.. ;-) We will use our dowel points to align 2 holes so that a pair of small dowels can hold the bottom.
– Rest the the Front Panel assembly on the carcass piece “BB1”. Mark a small vertical line with a straight edge 2 feet in from each edge of the assembly.
– Practice with the dowel points first on a test piece. Drill a 1/4″ hole in the edge of the Front Panel Assembly along the line you just drew. Repeat at the other location. Insert the 1/4″ dowel point into the holes. Put the Front panel assembly into place exactly where you want it. Press down hard and 2 impressions will be made in the top of “BB1”.
– Drill 1/4″ holes in these 2 impressions. Insert 1/4″ dowels into the 2 holes. Fit Front Panel Assembly and ensure that it mounts into “BB1” securely.
– Apply 3 pieces of good quality stick on Velcro onto the top inside of the front Panel Assembly and the “FS” bar.
chose to use extra heavy duty drawer glides. You could probably find lighter duty drawer glides that would work for your DVD/CDs. For the components, you should stick with the heavy duty stuff. Because the hinge and open door will be in the way when the drawers pull out, we need to pad out the glides on that side. We do this with 3/4″ wood cut to the width of the glides.
Two guide support pieces are needed on the right side because I have a piece of wall molding on the right side of my application that I needed to clear. You may have a different application and can modify your glides mounts.
4 RGS1 Right guide support 20 ½ x 1 ½
4 RGS2 Right guide support 24 ¼ x 1 ½
1 LGS Left guide support 24 x 1 ½
– Starting on the left side component opening, cut 2 template blocks at the height that you want the bottom of your component shelf to be, as shown in the picture below. Starting on the left side, rest the “LGS” piece on the template blocks and mark a line along the top of the “LGS” piece to hold your position. With a raw glide, do the same on the right of the component opening to mark a line at the top of the glide. The 2 glide heights should be at the same height now with respect to the component opening bottom.
– On the drill press or workbench, drill counter sunk holes through the “LGS” piece to attach to the left side component space. Attach the drawer guide to the “LGS”. Remove the drawer glide. Attach the “LGS” to the inside left cabinet below your line. Attach drawer glide again.
– Attach the drawer glide to the inside right edge below your line. Slide in inside parts of both drawer glides. Measure inside width to check that drawer bottom measurement is good.
– For the right door drawers, the right side will use the “RGS1” and “RGS2” pieces. Set up those two pieces as shown in the top drawing. Mark the pieces where they meet so they will line up together. The idea is that the 2 pieces are needed to get around the “HSB” piece. We will build up an assembly with the “RGS1” and “RGS2″ pieces and the drawer glide. We will attach the assembly tot he cabinet from the right most OUTSIDE cabinet. This makes it easier to get the piece on without having to work in the narrow 11” space…
– On the drill press or workbench:
a) drill holes to attach the drawer glide to “RGS2”.
b) remove drawer glide from “RGS2” and drill counter sunk holes through the “RGS2” piece to attach to the “RGS1” piece.
– repeat a) through b) for the other 3 pieces.
– Make 2 template piece for each height as shown in the picture below. With the right drawer glide assembly all together, rest each one on top of the template pieces at the exact height you want. Mark a line inside the cabinet. Drill a few small holes through the right cabinet wall below the lines. Go to the OUTSIDE right cabinet and drill countersunk holes.
– Rest drawer glide assembly on the template guides. Secure them with screws from the OUTSIDE.
– Repeat for all 3 remaining drawer glide assemblies.
– When this looks good, remove all 4 drawer glide assemblies.
– Set up the templates on the left side and mark the top of the glides. Attach the drawer glide to the inside right edge below your line.
– reattach right drawer glide assemblies. Slide in inside parts of both drawer glides to all 8 glides. Measure inside width to check that drawer measurements are good.
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