Master Bath Cabinet: Progress

I hesitated to title this post Progress, because at times this weekend it felt like anything but progress. Since 2010 is going to be the year where I learn from my mistakes, I won’t lead off with that. I’ll post the list at the end for those that may be interested or those looking for affirmation that they are not the only ones who make mistakes.

I milled the door frames last weekend. To safely cut the grooves for the door panel I needed a zero clearance throat plate for the table saw.  The one that came with my bench top table saw was way too open.   I’ve needed one for some time, but the shape of the throat opening in my table saw is odd and I couldn’t find anything available ready made. I bought a piece of phenolic plastic and milled it up this weekend.

I cut the first one using the router table and a plunge router. Way too much work. Once I had one made for the dado cutter I used the table saw to quickly clear the material for another one.

I figured this would be a good opportunity to try my new thin kerf Forrest WoodWorker II blade. I bought it awhile ago when it was on sale for a really good price, but have been having really decent results with 60 tooth blade I picked up at Home Depot for about $25, so I have been reluctant to switch. I only made a few cuts on ply for the door panels, but so far I like it.

So back to the cabinet doors. I assembled the first one, no problem. I assembled the second one and one of the rails is ever so slightly short.   How it got that way is a mystery.  I cut all four pieces with a stop block at the miter saw and checked them all when I laid out the frames.  Anyway, after messing around for an inordinate amount of time with the hinges, I got it pretty close.

So, truth be told, I was a little disappointed with the doors, but it will be OK. The perfectionist in me just saw it coming out a bit different.

So, here’s some things I learned this weekend that I hope to remember  next time 🙂

1. If you build it from the cut-off pile, you have to expect some issues.
2. If you put off building jigs you need (to work safely), you are going to have your project put on hold when you are most anxious to move forward.    Worse yet, you could get hurt doing something you know you shouldn’t do.
3. Adjustable hinges were invented to keep you from going insane when trying to align doors.  Friends don’t let friends  use cheap hinges.
4. Alignment and orientation marks on the wood are a good thing, but only if you pay attention to them when you join everything.
5. Revisiting your reference materials from time to time is useful.  I reread my router table manual and my plunge router manual this weekend and picked up a few adjustments beyond the basics.  I also reread the drawer chapter in Rae’s Cabinet Construction book to help me figure out design for my next project.