Well, Pat, I built a vanity as a test piece over the weekend, and decided Sat. night that I'd just get one of these jigs to try the process. I can't immediately recall the model number, but it's the $45.00 set that has the Two-hole jig, the collared drill, and the long square bit all boxed together.
That thing is at least 50% slicker than owl shit! I just couldn't believe how quickly and easily I got the face frame built, and it made adding some gussets in the top of the box an absolute breeze. If I'd gotten no other tips at all from all you fine people, (and I've gotten plenty), that would have made me happy as a clam.
Although I haven't had a chance to start finishing the door edges yet, I made two doors from 3/4 birch ply with rounded edges. I'm going to try a couple of purpose-made wood fillers, and if those don't give good results, I may try good old Bondo. The edges are smoother in the raw state than I'd expected, so I'm pretty hopeful at this point that I'll get decent results without having to add frames around the plywood.
Some thoughts from the work this weekend:
If I had a table saw, I'd buy poplar boards and mill them to size. Since I don't, I'm spending more for milled stock for the face frames at Lowe's. I'm OK with that, as it's not all that much stock to begin with.
A new finish blade on a circular saw that I've used every day for ten years, when driven carefully, is going to be quite acceptable for all my sawing needs. (except that I'll use my el cheapo jig saw to complete the cuts so as not to waste plywood)
I'm up to sixteen clamps now, and expect to get more before long.
I need a couple of extra arms for getting everything into position to clamp. Some of the scenes on Sunday would have made you guys split a side, laughing. :)
I was nervous about starting this project. As I get further into it, though, I find I'm starting to really enjoy it. Thanks, everyone who has chipped in with tips and advice! I'll keep you posted, and I'm sure I'll have more questions as I get on with the build.
Luke
Pat Barber wrote: