Entertainment Center Plan

  1. Side Assembly
    1. Rip and crosscut the side stiles and rails to size (#1-5).
    2. Plow stopped grooves in each stile with a bearing guided rabbeting bit. Grooves are 1/4" wide and 3/8" deep.
    3. Center a groove in the appropriate edge of each rail.
    4. Mill tenons and trim 1/32" off each.
    5. Dry fit the pieces, apply glue to rail tongue, and clamp.
  2. Back & Fixed Shelves
    1. Clamp straightedge in place to plow fixed shelf grooves in each side
    2. Rabbet each side assembly for the cabinet back using a router. Rabbet is 1/2" wide and 1/2" deep.
    3. Cut the back and fixed shelves to size
    4. Glue and clamp fixed shelves in place. Shelves should stop at edge of rabbets that were just cut for the back
    5. While the glue was dries, stain the inside of face of the back
    6. Use a template to drill shelf holes in stiles for adjustable shelves
    7. Fit the back into its rabbets and nail into place using 3d finish nails
    8. Attach front top rail using 3d finish nails
  3. Top
    1. Cut top (#11) to size, lay it in place, and mark locations of back, sides, and front
    2. Rabbet edges for clean fit
    3. Glue top an nail in place
    4. Route top with flush trimming bit
    5. Install mitered edge caps with glue and nails
  4. Front Frame
    1. Crosscut front stiles.  Note that piece #14 is cut from one piece so that the grain of the front stiles will run the full height of the cabinet.
    2. mill tongues on ends of lower and center rails (#s 15, 16)
    3. Transform tongues into tenons by trimming shoulders
    4. chop mortises in stile using Forstner bit and cleanup with a chisel
    5. Dry fit lower frame, apply glue and clamps
    6. When dry, sand frame, and install with glue and nails
  5. Hinged Stiles
    1. Mill mortises for butt hinges.  Do so freehand with a router then cleanup with a sharp chisel.  Note that the screws for hinges must be 1/2" or less for the front stile, or they'll blow right through
  6. Doors
    1. Plow a groove along inside edge of both #19 stiles using a bearing guided rabbet bit
    2. Make similar grooves on inside edges of top and bottom door rails (#20)
    3. Mill tongues on ends of rails using same table mounted rabbeting bit, holding each part against with a piece of scrap between part and gauge.  This prevents tear out at the end of each cut
    4. Dry fit, then assemble doors with clue and clamps
    5. Install door using Soss™ invisible hinges (#22).  Follow the instructions with patience.
  7. Drawer Box
    1. Mill finger joints
    2. plow grooves for drawer bottom (through on #24 and stopped on #23)
  8. Drawer Front and Installation
    1. Cut stiles and rails to size ( #s 26, 27)
    2. Use rabbeting bit to plow groove along inside edge of each part (through on #27, stopped on #26)
    3. Mill tongues and trim shoulders
    4. Cut panel to size (#28)
    5. Dry fit, glue, and clamp
    6. Make a pair of L-shaped cleats (#s 29, 30) and attach drawer slides to these cleats following manufacturer's instructions
    7. Clamp cleats to workbench the same distance apart as they will be in cabinet.  Attach slides to drawer making sure to mount drawer high enough to clear lip at bottom of its opening.
    8. Screw and glue the cleat/slide subassembly in place.  Drawer slide should be absolutely flush with back face of cabinet frame
    9. Cut 1/4" plywood scrap a hair smaller than viewable area of panel in face
    10. Stick 2-sided tape to drawer front, and place a couple of 4d nails in the bottom of the opening as spacers.  Center the drawer face in the opening.
    11. Open the drawer and screw the face to the front
    12. Be sure to attach the pull before closing the drawer
  9. Adjustable Shelves
    1. Cut front edges of shelves to size
    2. Attach to relevant shelves using glue and clamps
  10. Media Tray
    1. Cut large rabbets for drawer slides (#40) in pieces #39
    2. Plow grooves in #39 and #42 for drawer bottom
    3. Cut tray bottom to size
    4. Miter the molding to length
    5. Dry fit and glue up tray
    6. When dry, install slides
    7. Assemble black plastic media holder (#43) then lay them in place
  11. Finish Up
    1. Apply 3 coats matte polyurethane-based finish, sanding with 400 grit between coats
    2. Reinstall hardware after finish is dry
    3. install back vents, door pulls, and wiring grommets (#s 44-46)
    4. Install a couple of 3/4" cherry cleats (#47), gluing them to the back of the cabinet front frame, at the top and bottom of the opening
    5. Mount magnetic catches (#48)

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