Anyone interested in 83 Pace Arrow Tear down and Rebuild?

Don't you need 1 more horizontal piece across the top? Might be easier to put in on before you fasten the face frame to the cabinet.

So, with all that fiasco, where did I end up the day?

HERE!







The cabinet front is not glued to the plywood, yet, but the rest of this is glued and screwed together.

So, hopefully, again, tomorrow, I can glue this into place and move to the other side.

In case you wonder why things take extra time, sometimes, well, it's just little things like today's episode!

That also created this scenario, where the head of the screw stuck out just a touch on the back side. Depending on how I held the screw and the driver, I managed to eliminate nearly all of that.

I decided to live with it, since it won't be seen anyway.

Unfortunately, that also created this scenario, which moved the hole in the bottom a little nearer the edge, but still workable.

So, I moved the stop on the drill bit, until I finally got the depth of cut to where I liked it.

Here you can see, after trying different height pieces of plywood, I finally got the bit to start drilling on the side, and not the top. (yellow oval).

However, that also moved the bottom of the hole downward to the point where, it would do no good, strength wise. (red oval). Fix one problem, create another one.

Soooooooooo, after some fumbling around I cut a piece of plywood, that was 3/8" thick, and stuck it under the walnut in the Kreg jig. That seemed to cover up the hole in the jig, so that when I started drilling, it would drill into the side and not the top.

Here's what the drill bit sees.

It turns out, that the jig is made for stock that is roughly at least 2" wide. If it's not, the drill will do exactly as above. Start drilling through the top of the stock.

Bummer. I have all these rails and stiles cut at 1.5" wide, so I am kind of stuck with them, so all I can do is try to make this work, with what I have.

Yes, I have more walnut available, but I am not interested in wasting what I have, and it is just a touch over 1/2" thick, so if I glue it together width wise, then I'll need to plane it even thinner to make sure the surface is level.

Ah, yea, not going to do that. I am going to use what I have.

After some mental manipulation, I discovered how a 1.5" wide piece of wood looks to a Kreg jig.







As you can see, the hole for the drill bit, starts much higher than the board does. Oops...

When I drilled my first hole, it ended up looking like this....







Yea, the beginning of the hole, started, not on the side of the rail, like I expected, but down through the top. Say what?