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Repeat step 5 for the right hand panel. Remember that this panel is larger due to the
fact that the right side of the front frame is also taller.
7. Build main frame
Now that the two sides, front and back have been built, it is time to put them together.
Sandwich the left hand side panel between the front and back panels and screw the
three pieces together by driving screws through the front frame into the side as well as
from the back frame into the side panel. Then attach the right hand panel to complete
the frame. Make sure that the completed frame is square.
8. Add middle panel
Next, add the small middle panel, gluing and screwing it into place. This panel should
fill the small void at the point where the front/back steps up from the lower height to
the taller level. At this time you should also add a small strengthening bar to the
bottom middle of the frame, running from front to back. To add it, glue and screw into
place from the front and back.
9. Add tops
The final strengthening trick is adding to table tops. First add the larger, lower top.
This should overhang the front and left hand side by 1", over-hanging the back by
1/2". To attach this top, glue and nail - or screw - down into the frame.
Add the smaller top to the higher part of the table next. Again, the overhang should be
1" to the front and both sides.
10. Add edging strip and molding to top
Add the edging strip to front and sides of both tops. Use glue and small finishing nails
to hold the strip into place against the plywood edge of the table top. Next, add the
small molding to the meeting point between the top and the main frame, thus making
the two look more like one unit.
11. Make base panel and attach to base.
To finish off the main unit we need to add a base board that will serve as feet. This is
one solid plank that runs the entire length of the unit. Route a curve out of the top side
to round it off (see diagram). Add to from and sides - using a mitered cut at each end -
using screws and glue. The board should overlap 1" with the frame, providing
adequate bonding space.
12. Make drawers
Take the two side pieces, the back and the inner front piece. Cut a groove in each one
that is 1/4" from the bottom of each piece and is 1/4" wide. This groove will allow the
base to slot into the drawer frame. Once you have cut the groove, glue and screw the
sides to the back piece, slot the base into the groove and then glue and crew the inner
front board. Make sure that the unit is square. The result is a box without a lid.
Attach a 16" drawer runner mechanism to each side of the drawer, and to the
corresponding "hole" in the main unit of the chest. Ensure that all drawer mechanisms
are attached at the same height, so that the drawers are interchangeable in the unit. To
attach the runners to the main frame, you may need to add a strip of wood to the rear
verticals.
Finally, you need to add the front of the drawer to the box unit. However, before
doing this, you need to shape the front of the drawer. The edge of this should be
rounded using the same router bit as you used for the edging around the bottom of the
main unit. Once you have routed all four sides of the drawer front, attach it to the
drawer unit by gluing and screwing from the inside of the drawer outwards.
13. Finishing
Finally, nail the two back panel pieces on to the back of the unit and sand the entire
unit thoroughly and paint.
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