Well, spent the last two holiday weeks getting the lower part of the ent. center complete. Here was the original design I posted a while back:
I completed the bottom two rows. Each row is three boxes made out of 3/4" birch plywood.
Here's the simple setup I have in my garage - a BT3100 with dust collection above and below and a movable folding workbench.
Here's a pic of the sanding setup I used.
Pretty dusty but could be worse. Here's the pocket hole setup. I used 6 pocket holes along the 20 inch depth.
Really nice and easy using the Kreg system (my first time). Here's the clamping setup to set the screws. I relied on the plastic L's to keep things square and it seems to have worked out fine.
Next I filed the pocket holes to make the plugs fit easier.
I found that cutting off some of the plug length reduced the sanding requirements a lot. Here's how I cut the plugs with a Dremel. I held the plug with my vice and some tacky cloth. Not the best setup but it was all I could think of.
Here's the tools for placing the plugs.
I needed to hammer the plugs to seat them well but it didn't matter since I still had to sand some. Here's the hammered plugs.
The upper row has boxes 42" wide and I felt they might sag so I added a small 1" wide brace on the back.
The brace is inset a bit since I routed a groove around the box to inset the backs.
Here's a shot of all the dust thrown by the router.
Here's what the completed back looks like. I used 1/4 plwood on the top row and 3/4 plywood on the bottom for more strength.
Here's what the second row looked like once I put it on.
Now on to the face frames. I cut a clear 1x10 pine board down and used glue and brad nails.
I added more braces to the front of the 42" long boxes on the top row since it seemed to need it. Here's the final photo of what I've finished so far.
For the bottom, I ran two 8 foot 2x4's along the bottom and attached felt sliders. It moves easily on my fake wood floor.
Now my wife has to make the final decisions on the sides.
I completed the bottom two rows. Each row is three boxes made out of 3/4" birch plywood.
Here's the simple setup I have in my garage - a BT3100 with dust collection above and below and a movable folding workbench.
Here's a pic of the sanding setup I used.
Pretty dusty but could be worse. Here's the pocket hole setup. I used 6 pocket holes along the 20 inch depth.
Really nice and easy using the Kreg system (my first time). Here's the clamping setup to set the screws. I relied on the plastic L's to keep things square and it seems to have worked out fine.
Next I filed the pocket holes to make the plugs fit easier.
I found that cutting off some of the plug length reduced the sanding requirements a lot. Here's how I cut the plugs with a Dremel. I held the plug with my vice and some tacky cloth. Not the best setup but it was all I could think of.
Here's the tools for placing the plugs.
I needed to hammer the plugs to seat them well but it didn't matter since I still had to sand some. Here's the hammered plugs.
The upper row has boxes 42" wide and I felt they might sag so I added a small 1" wide brace on the back.
The brace is inset a bit since I routed a groove around the box to inset the backs.
Here's a shot of all the dust thrown by the router.
Here's what the completed back looks like. I used 1/4 plwood on the top row and 3/4 plywood on the bottom for more strength.
Here's what the second row looked like once I put it on.
Now on to the face frames. I cut a clear 1x10 pine board down and used glue and brad nails.
I added more braces to the front of the 42" long boxes on the top row since it seemed to need it. Here's the final photo of what I've finished so far.
For the bottom, I ran two 8 foot 2x4's along the bottom and attached felt sliders. It moves easily on my fake wood floor.
Now my wife has to make the final decisions on the sides.
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