I decided to build some cabinets for dust free tool storage. I've seen quite a few examples of turn of the century Doug fir cabinets in the salvage yards around Seattle. A lot of these come from old schools or other public buildings. I like the institutional look and the simplicity of the design. The doors often have Douglas fir plywood panels. I cant help but notice the quality of the plywood from back in the day. After sorting through the entire 1/4" marine grade fir plywood stack at the local lumber yard I still ended up with football patches on my doors. Maybe in 100 years when my cabinets are sitting in a salvage yard some one will look at them and think of a time when they still made fir plywood.
This was the insperation
This was my original Sketchup model. I considered wired safety glass for the doors but the guy at the glass shop informed me that it no longer qualifies as safety glass and is hard to find. It is still produced but in small batches and has the small batch price tag of $25.00 per sqft. I decided to stay with Douglas fir plywood panels.
Here are the rails and styles with the dado for the panel and the open mortise and tenons. I started with 1x6 S4S CV fir stock. I cut the dado on the table saw with the stacked dado head. I was able to cut the open mortise on the styles with the same arrangement and a tenoning jig. I switched over to a standard combination rip and crosscut blade for the tenons on the rails. I used a miter sled for the shoulder cuts and the tenoning jig for the cheek cuts.
Here is a close up of the Open mortise and tenon or bridal joint.
Here are the staged components of a flat panel door.
After dry fitting the assemblies and sanding the panels I glued and clamped the doors.
Ready for dowel pins.
I built the Carcasses out of 3/4" ac fir plywood. They are held together with half lap joints , glued and nailed. I used 5/8" galvanized shelf standards for the inside of the cabinets and also on the two opposing outside faces for a shelf that will be installed between them. I cut the dado's for the standards at the table saw with the stacked dado head cutter. The insides of the cabinet got two coats of arsenic green to complete the institutional look.
I mortised for the but hinges with a trim router and a 1/4" straight cutter. I like to layout the mortise and route out most of the waste free hand and then clean up with a chisel. After hanging the doors I installed the pulls.
Finished with shellac and bolted to the container walls with stainless steel through bolts. A dab of caulking on the bolt head on the outside of the container seals the can back up.