Rebuilding a Broken Kitchen Drawer

My brother in law had a kitchen drawer fall apart on him after years of use. The drawer was built with mitered corners, which don’t make much sense in this application, because they’re essentially butt joints. As such, every time somebody pulls the drawer open, the entire force of the action is put on the glue that holds the side and front of the drawer together. Glue is strong stuff, but the drawer box was made out of particle board, which isn’t, and over time, the joints let go.

I tackled the repair by rebuilding the drawer box out of 1/2″ MDF, using drawer joints (yes those are a thing) in place of the mitered corners on the original drawer. Here’s an image that I blatantly stole from the internet that shows the type of joinery that I’m talking about:

As you can see, the two sides of the drawer hook together with a sort of mortise and tennon joint. The uppermost board in that image would be the front of the drawer that I made, while the lowermost board would be the side. Whenever somebody pulls the drawer open, the force of the action is distributed throughout the joint, and the wood that makes it up, instead of being focused entirely on a glued butt joint.

My brother in law was really happy with the way that the drawer turned out, and I got a chance to try out some new joinery that will definitely come in handy sometime down the road.

SlightlySauced Episode 205: Robotic Space Millenials

In this episode we’re all over the place – from self-landing rockets to colonizing the moon to old media formats and finally to how you too could buy a house and quickly pay off your mortgage if you weren’t such a lazy millennial! Send us your feedback and we’ll feature it on the show!

Get it wherever you download talk radio for the internet age:

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Thanks for listening!

SlightlySauced Episode 204: There Go Our Jobs

In this episode we discuss a variety of topics from military spending, racist trademarks and our future job perspectives. It’s a bird, it’s a plane, it’s… well actually it is a plane but should we still be buying it? A band tries to register their contentious name as a trademark but should they be allowed to? Jobs are fleeing the country but is it really Mexico or China’s fault? Listen to our thoughts and don’t forget to send us your feedback!

Get the show from wherever fine podcasts are sold:

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Thanks for listening!

Fixing Broken End Tables

Awhile back, I made some end tables out of a couple of old pallets that were hanging around my workshop. Unfortunately, due to an inherent flaw in the design of these tables, one of them developed a pretty serious crack after just a few months of being inside of my house:

In order to fix the crack, I had to cut the table top apart and replace the broken pieces, and then rebuild the mitered maple frame that encircles the piece. Speaking of the frame – commenters on both Reddit and YouTube helpfully pointed out that it’s actually the cause of the issues. Basically, the laminate pieces that make up the table top will expand and contract across their grain as the humidity in the room changes. The maple frame that encircles the table top holds them in place, preventing them from moving. If the forces within the table top get too strong, the wood will crack to relieve the pressure. So, stay tuned for part three of the end table saga wherein I totally rebuild the table tops? We’ll see how long they go before cracking again.

SlightlySauced Episode 203: Pure Asteroid Cigarettes

Through the magic of pre-recording this episode of SlightlySauced continues on where we left off from last time! NASA plans to mine an asteroid – better call Bruce Willis! Jason Kottke writes a blog about things you should probably know – and we talk about some of them! Mennonites are getting a bad rap again – and Weird Al isn’t to blame this time! And more! !!

Grab the show from wherever you get podcasts:

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Thanks for listening!

 

SlightlySauced Episode 202: Cannibal Spiders from Hell

On this episode of SlightlySauced we talk about all sorts of crazy things – if that wasn’t already immediately apparent based on the title of the show – and give you some of our recommendations on cool things to check out. More of the ‘classic’ cast rejoins us and we even have some listener feedback!

Grab the show from your internet of choice:

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Thanks for listening!

Wood Working Basics: Table Saws

After my first couple of project videos, I got some feedback saying that I was using terms that viewers weren’t familiar with. With that in mind, I decided to make a series of videos that serve as introductory pieces to various wood working topics.

The goal is to highlight a particular tool or technique, explain its vocabulary, and why it’s useful in the shop. This is a good first shot at that concept, but I think I can improve on the idea in future videos.

Let me know if there are any terms or tools that you’d like to see in a future Woodworking Basics video.

SlightlySauced Episode 201: Don’t Call it a Comeback

Two years after going on an extended hiatus, SlightlySauced is back! It was great to get back on the mic with two guys that I’ve been hanging out with since high school.

The show is available wherever you internet:

  • Direct Download (right-click and save as, or open in a new tab)
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Thanks for listening!

Apprentice Marks Makes: Fancy Record Crates

Like many hipsters, I’m not just a computer programmer who practices woodworking on the weekends, maintains an excellent beard, and spends far too much money on craft beer. I also collect records, and my original record storage solution has recently overflowed into a pile of records that are sitting on top of my record player. It’s time for something new.

The design, pre-finish, and without the end cap panels installed

The design, pre-finish, and without the end cap panels installed

To accommodate my collection, I decided to build three boxes. Two with inner dimensions of 13″ cubed, and one with inner dimensions of 13″ x 13″ x 18.5″. The larger crate is about 1.5x wider than the smaller crates, and was intended to stack on top of the two smaller ones, which would sit side by side.

To make the crates visually interesting, I decided to make the ends like picture frames, with a different colour panel inserted into them to break up the negative space.

Cutting the frame edges to length

Cutting the frame edges to length. I chose 13″ as my inside dimension, because it would allow the boxes to accommodate even my largest box set records.

The frames were made from some rough poplar that I got from a tree that my dad cut down some time ago. The poplar was rough sawn when I got it, so I jointed it, planed it, and cut it down into 13″ x 1.5″ x 1.5″ strips that would form the frame edges.

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The jig is made of some 1/2″ plywood and is glued and tacked together. In retrospect, it should probably be longer, to prevent it from tipping forward or backward as it is pushed.

With the edges cut to size, I used a simple jig that rides on top of my table saw fence to cut the mortises on one end of each strip. This jig allowed me to clamp the piece vertically, so that I could push it through the saw without fear of it rotating, and without getting my hand anywhere near the blade. It’s basically a super-cheap homemade version of a tenoning jig.

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I have two crosscut sleds: One for my 1/8″ blade, and another for my 3/8″ dado stack

I cut a tenon on the other end of each edge using a simple crosscut sled with a stop block and a dado blade. To make sure that the joints fit together tightly, I started the dado blade lower than necessary and snuck up on the perfect width for the tenon. Just to cover my ass, I cut one extra edge for testing so that I didn’t have to fear ruining one of my production pieces.

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There are only five frames in this photo. I have no idea where the sixth one went.

With all of the joinery complete, I assembled the frames with some carpenter’s glue. One nice aspect of assembling a frame with mortise and tenon joints instead of mitred corners is that it’s dead simple to get the frames square. As long as the joinery is square, once the frames are clamped together, there is very little adjustment needed to ensure that each of the interior angles is 90 degrees.

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Once the glue dried, I used a chamfer bit at the router table to soften the outside edges of the frames. I could have used a round-over bit here, but I wanted to leave the hard lines on the work, because they are meant to look sort of industrial and heavy, and I thought that soft edges would ruin that look.

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Next, I used a rabbeting bit to cut a 1/4″ square rabbet along the inside rear of each frame. This is where the insert will sit, similar to the glass in an actual picture frame. If I were doing this again, I think I would have cut this rabbet at the table saw. The router made a real mess out of some of these cuts, chipping and tearing the wood away from the finished edge.

I asked a woodworker friend about it, and he told me that the cause might actually be the variety of the wood that I was using. He said that there are some varieties of ash that are often mistaken for poplar, and that they have a tendency to chip and tear. I guess that’s a risk that you take when using free lumber.

An assembled panel

An assembled panel

With my frames complete, it was time to build the panels that were to sit inside of them. I picked up some cheap knotty pine wainscotting from my local Home Depot, cut the pieces to a 10.5″ length, glued them into panels, and then cut the panels to their final size. I used a dado blade to cut a 1/4″ rabbet around the outside edge of each panel, which will correspond to the rabbet that I cut into the frames, giving me two flat surfaces to glue together.

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Now that I had all of the pieces assembled for the ends of my crates, I needed some way to tie them together. I bought some 1″ x 8″ x 6′ clear poplar boards and cut them down into strips 1.5″ wide and 1/4″ thick. The two smaller boxes required 42 strips cut 14.5″ long, while the bigger box required 21 strips cut 19.5″ long.

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I used a 3/8″ wide piece of scrap to ensure that the spacing between strips was correct

I used carpenter’s glue and 3/4″ brad nails to tack seven strips to three sides of each set of frames. This was easy enough, albeit time consuming, once I figured out how to jig my frames up to keep them square to one another during assembly.

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After a thorough sanding, I stained each of the boxes a deep red, and then glued the wainscoting panels into the frames. A coat of spray-on fast drying polyurethane will protect the boxes from incidental bumps and scratches.

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After letting the finish cure for a day, I brought the boxes inside and re-organized my collection. They look great, and leave me plenty of space to fill up with even more records.

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Stay tuned for the inevitable follow-up project, wherein a I build even more storage space for the records I will definitely buy over the next year or so.

Apprentice Marks Makes: Pallet Wood End Tables

This project started with a couple of hefty solid wood pallets that I got when my local Home Depot delivered some renovation materials to my home. They were each around 40″ square, and were made of what seemed to be a range of hard wood varieties.

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I started at the pallets with a hammer and a crow bar, but soon resorted to cutting the deck boards off with a circular saw, as my prying was doing a lot of damage to the dry wood. Two pallets yields quite a few usable boards:

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After a few hours of jointing, planing, and table sawing, I had processed most of the deck boards into thin strips, about 3/4″ square, that would be glued together to form laminate tops for my end tables. I made sure to hold a few boards back for building the frames of the tables.

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The goal was to make two end tables, each with a table surface of about 24″ x 24″. since I intended to put a 1″ mitred border around the outside of each table top, I needed to make two 22″ x 22″ laminate pieces out of the strips that I had cut from the deck boards. I wanted to use my bench planer to clean up the laminate pieces, so I started by gluing the strips into four 22″ x 11″ boards.

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After letting the glue cure overnight, I ran each of them through my planer to ensure a smooth surface and a uniform thickness. Next, I ran one edge of each piece across the jointer, and then glued jointed edges together to form two larger boards, each approximately 22″ x 22″.

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Level added for rigidity. It turns out it’s hard to keep a seam in the middle of a 22″ piece properly aligned. I guess that’s what biscuits are for.

After letting the glue cure again, I cut each table top to its final dimensions. Because the boards that I recovered from the pallets had nail holes and other imperfections in them, my table tops inherited some “character”. To ensure a smooth surface, I filled the nail holes with epoxy and sanded them flush.

Next, I cut some strips of hard maple out of some scrap that I had up on my stock shelf. These strips got mitred corners, and were affixed to the edges of each table top using glue and brad nails.

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With the table tops finished, I moved on to the table frames. The original intent of this project was to use reclaimed pallet wood for every aspect of the tables, but getting the nails out of the pallet stretchers (the big heavy pieces that separate the deck boards) proved to be a real challenge, and I didn’t want to risk missing one and ruining a tool with it.

The scrap maple that I used to edge the table tops had originally been cut from some much longer pieces that I got as a part of a used tool purchase back when I first started building out my workshop. I have been saving it for a worthy project, and figured that my first piece of real furniture was reason enough to rip some of it down into 2″ x 2″ table legs.

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I wanted to affix the table aprons (or stretchers – whatever you call the boards that run between the legs) to the legs with a mortise and tenon joint. I cut my mortises at the router, which left a rounded end to the cuts. I went back in with a 1/4″ chisel and squared them off. In the process, I learned that there’s a bit of technique to precision chisel work, and that I need a lot more practice at it.

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With my legs in good shape, it was time to turn my attention to the aprons. The apron boards were cut from some of the pallet deckboards that I had set aside when cutting up the laminate strips. At the tablesaw, I ripped them to 3″ in height, and used my box joint blade (sort of a simple dado stack) to cut a simple tenon on each end.

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With the fit looking good, I added an 1/8″ dado along the top inside edge of each apron. This slot will accept some table top fasteners that I bought off of Amazon. The intent of this hardware is give the wood grain that forms the table tops room expand and contract without cracking.

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The glue-up for the table frames was a bit stressful. I worked as quickly as possible, and tried to remember to wipe away all of the excess glue. My first timer joinery was mostly hidden in the process, which is probably for the best.

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Once I had the frames assembled and squared up, I clamped them to the bench and added some corner blocks to prevent them from twisting.

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After another overnight wait for the glue to cure, it was time to affix the table frames to the tops. Before doing so, I sanded everything down through 120 grit, 200 grit, and 000 steel wool to prepare for the finish.

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One of the things that I love about this project is the contrast of all the different varieties of wood that make up the laminate table tops. I didn’t want to lose this contrast when applying a finish, so I didn’t stain the wood at all. Instead, I just layered up some wipe-on polyurethane.

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Each table got two coats, and the table tops got a third coat for good measure. I sanded with 000 steel wool between each coat to remove any imperfections.

The finished tables look great in our living room. I’m really proud of the way that they turned out, especially considering that they’re my very first large furniture project. Now I just need to find time to build a coffee table to match.

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