Project #2 – Oak Nightstand
PLEASE SCROLL TO THE BOTTOM OF THIS PAGE FOR PROJECT DIAGRAMS
Side Panels
Quantity: 2
Final Dimensions: 7/8 ” Thick x 12” Wide x 20” Long
Material used: 1 1/16” solid oak
Steps:
1. Select 1 1/16” stock for glue-up. Glue-up should be slightly larger than the final size of the side panels (Rough Dimensions: 13” W x 21” L)
2. Joint all mating edges, reverse annual rings, and clamp overnight
3. Joint one edge of the glued-up panel
4. Rip the panel to 12 ¼” on table saw – place cut-off in scrap area to be reused
5. Surface plane the panel to final thickness (7/8”)
6. Cross-cut 1 end square on table saw
7. Cross-cut the opposite end of the panel to a final length of 20”
8. Top Rabbet: Select the tops of the panels and cut a rabbet 3/8” deep x 3/4" wide
9. Upper Dado (for drawer opening): Mill a 3/8” deep x 3/4” wide dado 4” from the top – the top of this dado should be 4” from the top edge of the panel
10. Lower Dado: Mill a 3/8” deep x 3/4” wide dado at the bottom of the panels - the bottom of this dado should be 2 ½” from the bottom of the panel
11. Joint 1 edge and rip the panel to final width (12”) on table saw
12. Back Rabbet: Mill a rabbet for the back panel. This rabbet should be 3/8” deep x 1/4” wide. MAKE SURE TO DOUBLE CHECK THE LOCATION OF THE BACK RABBET. IF IT IS MILLED ON THE WRONG EDGE YOU WILL HAVE TWO “RIGHTS” OR TWO “LEFTS”. YOU WANT TO HAVE 1 LEFT SIDE AND 1 RIGHT SIDE PANEL
13. Carefully trace the side detail cut with the template provided. Be sure to position the pattern so that all edges are properly aligned.
14. Cut out each side detail using the band saw – leave pencil lines slightly visible!
15. Remove all saw marks and sand up to pencil lines with the oscillating spindle sander and normal 120 grit sandpaper
16. Shape the detail cut with a roundover bit as demonstrated – use the router pad and do not let the router stop moving to avoid burning
17. Make vertical “V-grooves” with router table 4” from edges as demonstrated – be sure to make these cuts on the outside faces!
18. Locate and drill ¼” support holes ½” deep and 2” from each edge and 10” from the bottom edge of the side panels as demonstrated
19. Sand all parts of the panel before assembly
Fixed Shelves
Quantity: 4
Final Dimensions: ¾” x 11 ¾” x 18”
Material Used: 3/4” oak plywood
Steps:
1. Rip cut plywood to 11 3/4” wide on panel saw or table saw
2. Cross-cut to final length (18”) – make sure both ends are square
3. Apply oak veneer tape with iron to one edge as demonstrated
4. Flush trim edges of veneer with router
5. Sand all faces and edges
6. Dry fit side panels and fixed shelves – check for square!
7. Assemble case with glue and 1 ¼” brads – use 4 bar clamps and check for square! - Clean up all glue on project and bench
NOTE: SAVE 4th SHELF IN YOUR LOCKER FOR LATER USE AS A REMOVABLE SHELF
Baseboard
Quantity: 3
Final Dimensions: Qty. 1 piece for front-¾” x 3” x 21” (will be cut to fit)
Qty. 2 pieces for sides-¾” x 3” x 14” (will be cut to fit)
Material Used: ¾” solid oak or other scrap solid oak at least ¾” thick
Steps:
1. Locate enough ¾” stock to complete all 3 pieces – please check scrap rack first! If necessary, plane thicker stock to ¾”. Make sure all pieces are exactly ¾” THICK
2. Joint one edge of each piece, rip cut each piece to 3” wide
3. Cross-cut to final lengths (2 pieces @ 14”, 1 piece @ 21”)
4. Shape top (best) edge with shaper
5. Design custom cut-out for front piece – cut-out must be symmetrical and centered
6. Lay out custom design, trace, and cut on band saw
7. Sand custom cut-out and shape it using a ¼” roundover bit – use router pad for safety and use proper pace to avoid burning
8. Sand thoroughly before attaching baseboards
9. Miter corners to fit with miter saw as demonstrated
Attach baseboards with glue and brads
Sand miter joints smooth.
Top
Quantity: 1
Final Dimensions: 7/8” x 12 3/4” x 20 1/2”
Material used: 1 1/16” solid oak
Steps:
1. Select 1 1/16” stock for glue-up. Glue-up should be slightly larger than the final top size (Rough Dimensions: 13 ½” W x 21 ½” L)
2. Joint all mating edges, reverse annual rings, and clamp
3. Joint one edge of the glued-up panel
4. Rip the panel to final width (12 3/4”) on table saw
5. Surface plane the panel to final thickness (7/8”)
6. Cross-cut 1 end square on table saw
7. Cross-cut the opposite end of the panel to a final length of 20 1/2”
8. Shape both ends and front on wood shaper – do not shape back edge
9. Sand thoroughly prior to assembly – this will involve power sanders and hand sanding of the shaped edge
10. Place top upside down on bench, flip case upside down onto top, align the back edges, center the top left to right, clamp, and attach with four 1 ¼” screws
Drawer Pieces
Quantity: 4
Final Dimensions: Qty. 2 sides – 1/2” x 3” x 11”
Qty. 1 front – 1/2” x 3” x 16 1/2”
Qty. 1 back – 1/2” x 3” x 16 1/2”
Material used: ½” Birch Plywood
Steps:
1. Select ½” stock for drawer components
2. Using jointer, table saw, and miter saw, cut drawer parts to the dimensions listed above
3. Cut a ¼” deep x ¼” wide dado on all four drawer pieces for the bottom panel. This dado should be ¼” from the bottom edge of the drawer pieces
4. Cut a ¼” deep x ½” wide rabbets on the ends of the side pieces as demonstrated
5. Dry assemble the drawer and check the measurement for the bottom panel – the bottom panel should be 10 7/16” x 16 7/16”
6. Cut the bottom panel to size (make sure all edges are square) and dry assemble the drawer around the bottom panel (best face up). Check the fit and slide of the drawer in its opening
7. Sand all parts of the drawer before assembly
8. Assemble the drawer with glue and 1” brads. Only apply glue to the rabbets – do not glue the bottom panel in place – it “floats” in the dado
9. Ease the top edges of the drawer with a router or sandpaper as demonstrated
Drawer Front
Quantity: 1
Final Dimensions: 3/4” x 4 ¼” x 18 ¼”
Material Used: 3/4” solid oak or other scrap solid oak at least ¾” thick
Steps:
1. Locate a piece of stock to complete the drawer front
2. Joint one edge
3. Rip to 4 ¼” wide
4. Check thickness. Surface plane to ¾” if necessary
5. Cross-cut 1 end square, cross-cut opposite end to length (18 ¼”)
6. Rout front face with roundover bit in router – use router pad for safety, avoid burning!
7. Sand drawer front and edges prior to assembly
8. Center and attach drawer front as demonstrated using a nail gun and 1” brad nails– align the drawer front very carefully
9. Drill 13/64” or 7/32” holes for pull – 3” apart on center as demonstrated
Back Panel
Quantity: 1
Final Dimensions: ¼” x 17 15/16” W x 17 ½” L (tall)
Material Used: ¼” oak plywood
Steps:
1. Select ¼” oak plywood stock
2. Rip to 17 15/16” wide using panel saw or table saw
3. Cross-cut to 17 ½ ” using cross-cut table saw
4. Check fit on your nightstand. Grain goes up-down: trim as necessary.
Final Steps
1. Sand project thoroughly with 220 grit sandpaper
2. Stain all project components – includes case, shelf, drawer front, and back – do not stain the drawer itself – only the drawer front
3. Apply colored wood putty to nail holes, cracks, imperfections, etc.
4. Apply 2 coats of lacquer to all pieces – sand with 600 grit between coats
5. Attach back panel good face inward – use ¾” long nails or staples
6. Attach drawer pull as instructed using 8-32 x 1 ½” long screws
7. Insert shelf supports and install shelf
CONGRATULATIONS!