If only...

[bandit571]

It's getting there...

   
Dry fit for corner #3

   
A wee bit longer today, and..

   
Corner #4 is dry fitted...was trying to see IF I have enough clamps...

   
Nope...unless I use a lot of cauls.

Went to Lowes today...needed two boards...one for a shelf...the other to help build a drawer for the left side of the cabinet...Shelf will sit in a dado just above the drawer...means a STOPPED Dado between the front and back grooves...THAT should be a lot of fun to cobble up..Both new boards will get ripped down the center...with the shelf ripped again for final width..Easier to do it now, than wait until after the case is split...that way, the dados will line up.

The 2 panels I glued up..

   
Need a rebate run all the way around on the show face...to fit into the grooves in the Case.   with the show face of the panel flush with the outside edge of the Case..

Stay tuned...

[bandit571]

It would appear that I need to update this story a wee bit?
Needed to know where the shelf will be, decided to rip the 1/4" x 5-1/2" x 24" down the middle..

   
Wasn't quite perfectly centered, as I needed a 1/4" offset..

   
To allow for the drawer's bottom panel.  Then once I figured out how wide the drawer front needed to be..it got trimmed a bit..

   
Save that cut-off!  As it will be one of the drawer's sides..
So, set the drawer front near where it will be..

   
Then, lay out for the stopped Dados..

   

The shelf is 2 parts, and fits between the front and back panel.  1st rip on the 1/2" x 5-1/2" x 24" plank was to fit between the grooves, then it was ripped perfectly down the center line...they were then cut to length....and then a notch was cut..

   
So..how to cut a stopped dado..like these 2..?

   
There is a 1/2" wide chisel laying there...and it did 90% of the work...then the Stanley No. 71-1/2 was used...

   
A test fit was done...then another...

   
Then see how the shelf looks..

   
This was taken this morning, while I was gluing the entire case together...

Stay tuned..more to come..

[bandit571]

Those 2 panels, came out of their clamps....needed one end squared up. the other cut to length and square...there was an issue with width of the 2 panels..

   
One was a bit wider..we have ways..

   
Stanley No. 6c, WW2 era Small Jointer Plane....did not take very long...

Then, I used the tablesaw to mill a 1/4" x 1/4" tongue all the way around each panel...That tongue fits into the grooves in the sides, so that the outside of the panel is flush with the outside of the case...

   
Decided to try a full dry fit, without the shelf, for now..

   
Has a bit of room for any expansion that MIGHT happen. 

let this sit a day.....then this morning...

   
Cut a supply of cauls...even though I only used half of them...got out a cheap paint brush and a big mallet...Brush to spread glue wherever needed, and NOT on me.  Glue on a few fingers, to connect the bottom of the case to the 2 sides..but..I needed to splay things out a bit..I also slid one panel into the grooves, to stop the shelf from flying away...

   
Next? the other panel was slid into place, despite it having a slight bow downward, that I had to lift over the shelf...Then I could glue and hammer into place the top of the case..

   
Then it was time for the cauls and clamps, and a lot more cussing....when one caul is 18" away, being held there by a clamp, while I am at the other end of that clamp, trying to hold a second caul, AND tighten the clamp....second clamp on THOSE 2 cauls was a bit easier....then repeat the "Fun" for the other side of the case...

After that?   Almost every clamp in the shop LONGER than 18" was put in place....no cauls, had enough of that fun...so..

   
I used the bench's vise to hold onto things as I had to flip this over to do the other side...

   
Pipe clamps?  Nah, too big, too heavy, and most are too long..
Will let this mess sit a day..or 2...then remove that forest of clamps, clean the case up, including all then yellow stickers...and then set up to saw the case apart, into a front and rear case..which was the reason behind that split shelf...one less thing to saw through..and the reason for those stopped dados..

Stay tuned..

[bandit571]

Clamps removed..

   
Cleaned off the Yellow Stickers, and and all high spots..on both faces, then set to work on all the sides

   
Beginning with a block plane to ease all the sharp corners with..

One corner was missing a "finger", so..

   
Now you see it, and now..

   
You don't...

Once the sides were cleaned up and sanded to 220 grit, for now...needed a cut line,,

   
Centered on that fat finger...needed to find the center..

   
Hmm, that far?   Ok, set up the tablesaw's rip fence to be that far from the center of the saw blade..

   
And run each side of the case through...except for the last side...

   
I added a clamp to keep things from just flopping open on the saw...

   
Next up?    add the hardware...then see about a drawer?
Stay tuned..

[BpB123]

Thanks for the post Bandit!

I enjoy the ride along!

[professore]

As always, a ride-along well worth the trip.

Frank S in IA

[bandit571]

Laid out for 2 hinges...

   
Not sure what version Swan used, I happened to like bright Brass Hardware, so..

   
Chop 4 mortises..

   
Eggbeater drill for the 1/16" pilot holes...test to see IF they were laid up correctly..

   
And you can see why the shelves were installed the way they were..stopped dados for both shelves.

I did not have a keyed mortise lock, so..

   
I can add pad locks to these two, later...a front view?

   

Although the catalog picture showed the carrying handle on the left door..

   
I installed on the side that had the most weight of tools..

   
So....still need to make 1 drawer...for the left side...the right hand side was simply a wooden block that was drill to hold bits and other small things...these drawer are not very deep..

   
Hand is for scale...
So, next trip to the shop...I need to finger joint a drawer..

   
And decide on a drawer pull..

Stay tuned..

[bandit571]

Laundry Detail, last night...while standing around, waiting on the Washer to get done...
Front corners were done..

   
And a bit of a change up for the back corners of the drawer..

   
Was checking the fit of the plywood bottom..with a full dry fit..

   
Then a bit of glue, and....

   
A Forest of Clamps.....Washer finally "Dinged" that is was done...load was placed into the dryer..and I closed up shop...

This morning?   Intend to 1). Remove all them clamps, and clean the drawer up, and 2). Unload the Dryer, and haul the load upstairs...
Stay tuned..

[bandit571]

Forest of clamps has been put away.

Drawer has been cleaned up, planed smooth...

Found the center point of the drawer front, used a Brace & #4 Bit to drill a hole for a knob....was tight enough that I needed a clamp to seat the knob into place with a smear of glue...Test fit the drawer...

   

Then worked on a hanger for the chisels and the screwdriver...

   
May hold off on the hanger for the hammer...

Will see about a coat of Witch's Brew today....then a coat or two of varnish...tomorrow..

Hand saw went into a notch, so, I need to cut one into the shelf for the saw...

   
And see about a way to hold it's handle in place...

Stay tuned..

[stav]

Very fun.  

So what happens to the end of the saw there?  It looks like there is a full width drawer in the way. Is the drawer notched or does the saw hang into the drawer or is there some other config to allow them to work together?