April 20, 201115 yr Author I have no doubt in any of your recommendations Mike, Your the best. Reply by dragon1 10 hours agoSolid poplar or oak for face frames and doors is ok, your gonna need it all the way around to provide a flush face for the doors. And my screwed doors hold up just as well as a tenon joint on the corners.
April 24, 201115 yr Author Well we got some of the questions answered and they did change the door to 1/4" acrylic or plexi. They are getting that to match something that is already in use there. Anyway, my son went by the lumber yard last Thursday and picked up eight sheets of plywood, supposedly 3/4". Now I know 3/4" is only 23/32 but when we got all setup today to start, I took out my dial calipers and checked this plywood. It was only 11/16". The guy at the lumber yard told my son it was 13 ply, full 3/4". Well needless to say, we didn't get any of those cabinets built today and will be back over there on Monday to find out what happened. The 11/16 just seems like a little to much of a change and would mean I would have to adjust all of the drawings for the difference. Have you ever run into any 11/16 plywood?
April 24, 201115 yr It sounds like something from China. From what I have seen, they make the multiple ply plywood like that and it was 11/16 on some, different on others. Might be worth looking for Columbia plywood. made out in Washington. Very nice stuff. Sold by Menards around here. it runs about 45$ sheet for birch, a little more for maple. Do you have a plywood wholesale place you can buy from? bob
April 24, 201115 yr Author No, Bob, I wish we did. The was purchased from a United Lumber dealer. I thought they carried a better line of plywood than the big box stores here. We don't have a Menards here either.. I am disappointed in the ply from this place.
June 11, 201115 yr Author Well we did finally get some decent ply and I have been working on this along with my son for several weeks between so many other projects. I thought I would give you a peek at where we are. I am really under the gun as they are to be delivered either Wednesday or Thursday of next week. Today we have been getting all of the poplar edge banding sanded and going over the ply just lightly to knock off the fuzz. I don't have the backs in them as I am going to finish them and then install. Makes it easier to to the sides and shelves without bumping into the back. Â So I just sat them outside my shop for a picture. No room to sit them side by side in the shop. Â They are 16' from end to end. The drive is not flat and level so there are some gaps showing. This was just to sit them out and post an update. Â Will make the doors tomorrow afternoon. They are going to be big doors so I will probably do a half lap joint in the corners to help hold them and keep from sagging. Â Okay, well back to the sander and get them ready. John MoodyJohn Moody Woodworks
June 11, 201115 yr John2..After re-reading your original post and all the replies, how about you re-designing the cabinets using only width, depth and height and submit them to your customer.Seems like they want something, but don't know what it is..Larry Didn't see the latest images. Sorry, John..LarryÂ
June 12, 201115 yr Author About all I can say Larry, is that for the most part they are pretty minimal. My biggest concern has been making sure they fit the space when I wasn't the one that took the measurements. It has to sit into an alcove and I don't know if I have any wiggle room are not. I have them to the measurements that I got so I will keep my fingers crossed. We did make a small change on the door that was the original question to put in 1/4 plexi. My concern now is these door are quite big and I just don't want them to sag. I am going to see if I like either a bridal joint or half lap this afternoon and try to knock them out. They have not sent me the plexi to put in yet so that may be an onsite install. Delivery point is about 180 miles from where I live.Larry Jenkins said:John2..After re-reading your original post and all the replies, how about you re-designing the cabinets using only width, depth and height and submit them to your customer.Seems like they want something, but don't know what it is..Larry Didn't see the latest images. Sorry, John..LarryÂ
June 12, 201115 yr John,I would not use acrylic for your panels. It will scratch very easily. Scratches can be polished out but after a few months those panels may look pretty rough. Learned this the hard way with a couple small acrylic aquariums.
June 13, 201115 yr Author Randall, if it were my choice I wouldn't use them either. If you will look at the image at the top of the page and notice the side view. The second item down specs a red plexi-glass insert. I did get them to got with 1/4" instead of 1/2" but that is what they have specked for some reason and Red at that. They are suppose to be supplying it to me, but I don't have it yet and they want these installed mid week. They are going on a military base.John MoodyJohn Moody Woodworks
June 14, 201115 yr Author Got all of the door parts planed, cut to size and the rabbit for the glass cut. Started working on the bridle joints tonight. Got to finish them and get them glued up tomorrow. Got stain on part of the cabinets. Going to be a marathon to get finished. John MoodyJohn Moody Woodworks
June 15, 201115 yr Author Doors are all glued and in the clamps. The glass is suppose to be in tomorrow so I can get it mounted. Â Â I did a bridle joint on the corners to help hold them as square as possible and not sag. Each door is about 25"x 25" and will have a 1/4" white frosted plexi-glass. They didn't make the finial decision on the glass until yesterday so hopefully it will be in today so I can finish those tonight. They actually wanted delivery today, but that didn't work out. Â Got to get the top done and the upper bookcase. May be a long night tomorrow night. John MoodyJohn Moody Woodworks
June 16, 201115 yr Author Okay this afternoon has been really busy. I got all of the doors made, rabbited for the glass, hinges all installed and the backs in the all of the cabinets. Â Just need to sand the doors and get them stained and the toe kick piece stained. Â Everything is done except the bookcase for the end cabinet and the counter tops. Looks like I am going to miss the deadline. Part of it was their problem. Didn't get the plexi till today. Didn't get the hinge selection till yesterday. So I have a little more work and it will be done and hopefully delivered by the weekend. Â John MoodyJohn Moody Woodworks
June 16, 201115 yr Author Thanks Mike. It is getting there but taking too long. Hard to work 60 or hrs at regular job and get shop time also. They went with a white of frosted plexi. I left the paper on until I get it all sanded and stained then I will take it off and mount it in the doors. dragon1 said:Getting there John!!! Nice corner joints!!!Â
June 21, 201115 yr Author Okay so I got the plexi installed in the doors and we are about to wrap this up and get them shipped out. Â Â Â As you saw in an earlier post there is an open lower book case and I didn't take a picture before they left with them but there is also an upper book case. Â Will post a picture as soon as they send me some of them installed in the place they were going. I sure hope they fit since someone else took all of the measurements and I have never been where they are going. Â Â John MoodyJohn Moody Woodworks
June 21, 201115 yr Author Well I got one picture today of the cabinets installed. I understand all they like is putting the poly on them. There were going to do that on site after installation in case anything had to be touched up in transporting them. Â Â So it looks like the fit and the measurements were good. Â The contractor is going to install the hardware on the doors. It is something they are using in some other areas so they already had them. Â They will get polyed and have a new home. Â I'm thinking of all the New Yankee Workshop episodes I watched, Norm would be happy. Â It was a lot of fun to get to work with my son on this project. Stressful a few times, but a lot of fun. I am proud of the way they turned out. Maybe I'll get them to send me a better picture when they do the final cleanup and have them ready for display. Â Thanks for all of the input you guys gave, especially on the door. John MoodyJohn Moody Woodworks
June 21, 201115 yr Great job, John.. Especially with what you had to work with plan-wise. I have a question:Normally, stiles go top to bottom. I notice the rails are dominant. Did they want the doors made that way?Larry
June 21, 201115 yr Author Yes, she wanted to continue the straight line look that it gives across the top and bottom of the door. Thanks for asking. John MoodyJohn Moody Woodworks
June 22, 201115 yr Awesome John! What a neat project to do with your son. And as others have said, you did a heck of a job with the plans and the execution. I know you were putting in some long days on this project, on top of the actual build, I admire your dedication and I know it is rough coming home from work and then putting in some more hours on top of that. Way to go John, you guys did it! John MorrisThe Patriot Woodworker
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