DART BOARD CABINET

For father's day we got pop an electronic dart board. Instead of just hanging it on the wall I decided that I would attempt to build an oak cabinet to put it in. Having never undertaken case work I decided to build two at the same time. One would be a proto-type constructed from pine a much cheaper and softer wood. As I proceeded with the different phases of the project I built it first in pine then if everything worked out I did the same thing with oak.

I can tell you that I made a lot of trips to Lowes for more heart pine because I made quite a few mistakes. I can't believe no one has figured out a way to stretch wood after cutting it a quarter inch too short. Hmmm--guess I'll work on that in my spare time. Below are some pictures of the various phases of the project. These are only a few of the several hundred that I took. I'll post more as I get them sized.

Above left, I purchased a matched router bit set for raised panel doors. The two pieces of wood are my test cuts which now serve as set up pieces when I start to cut new rails and stiles. Above right, my first attempt at cutting a raised panel. This is the result of 5 passes as I raised the cutting bit a little each pass.

Here you can see the finished test panel and the joint that is cut in the rail (horizontal piece) and the stile (vertical piece). The joint should be tight and the pieces should line up perfectly, that is if you have cut the joint properly. This was my 4th attempt but I finally got the hang of it.

The picture below is my 5th attempt at cutting half blind dovetail joints. This is a very strong joint often used in the construction of drawers. Again after many trial and errors, I got it right.

I haven't started a project that has drawers yet but I plan to in the near future.

TOOLS

Below are a few of my woodworking tools. An 8" jointer, a 3-HP router and table, a dedicated mortising machine and a 5-HP table saw. I'm not very pleased with the router table and plan to build my own with plans that I got from the New Yankee Workshop. I really like the table saw it cuts even tough hard wood with ease. The 8" jointer is one of the best tools that I've ever seen. You can square up a piece of wood in no time and as I soon found out you can't build furniture with "off the shelf" wood.

After struggling through many attempts at cutting straight precise mortise joints I ran to purchase a dedicated mortising machine. I love this thing, cutting perfect mortises couldn't be easier. Like anything else, having the right tools makes all the difference.

THE CASE

The case was constructed from 3/4"x4" oak board joined at the corners with #10 biscuits.

The case stained and ready for the doors.

I stained the panels before I put the rails and stiles on. The panels ride in slots cut into the sides of the rails and stiles. No glue, as the panels need to expand and contract with the change of weather. If I glued them in they would eventually crack. The bottom picture shows the preciseness of the joinery.

THE DOORS

Before raising the front panels on the doors it was necessary to back cut the panels. This sets the panels back in the frames so the raised portion does not set as "proud". It also makes a nicer looking door. Below you can see how the door sets in the frame with the back cut. I back cut the doors 3/8". The doors, by far, were the most difficult part of this project.

Front of door with raised panel.

FINISHED CABINET

I put several coats of Tung Oil on the oak and let it dry overnight before applying 3 coats of urethane.