After laying out all the parts, I quickly discovered that 1x2 boards really aren't 1" x 2". Actually I knew that already but was reminded of that fact when I drilled the 1-5/8" screws through 2 1x2's and the screw hit the floor (oops). I returned to Eagle and got a pound of 1-1/2" screws instead.
In some places, I did have a problem with the 1x2's splitting when I screwed in the screw. If I were to do this again, I would actually pre-drill the holes for the screws just to keep the splitting down to a minimum. The places where it did split I just filled in the split with alot of glue. It seems to be working so I am not overly concerned about the splits (only happened in a couple places only). Driving the screw in slowly also seemed to prevent the splits.
Here is the final layout, with the original drawing next to it. When I got to this point, I realized that a couple of the pieces of framing were unnecessary so I did not include them. At this point, it was time to glue-and-screw the pieces together. I used my trusty t-square to make sure the bottom portion was square both before and after I screwed the pieced together.
After all that, here is one of the sides finished (minus the "filler" 1x2's to fill in the gaps). Even at this stage, the frame is still quite strong and should be able to take quite a beating!
The next morning I got started on the other side (just ignore the kiddie pool in the shot ). I laid the first side down and measured all the lengths and angles for the second side right off the it, using it as a template to make sure both sides are as identical as possible. Also note that I have not yet started to attach any of the filler pieces of 1x2 yet, I thought that could prevent me from getting accurate measurements if they were there.
Here is the result after getting all the filler pieces attached.
With the 2x6 base underneath, I am pretty sure this will be just the right
height. I have not bothered filling in most of the pieces with angles.
The only places where I did fill in with a second 1x2 are the places that
could support some additional weight or if they might be visible from the
front. The only places I did were the entire back side of the cabinet
(the longest side) and the place where the control panel area and the screen
monitor area meet (I have not yet decided how to finish that part yet,
better safe than sorry).
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This page last updated 9/7/99