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Compact Kitchen Island

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Deep rabbet for shelf panelToday we start off by making the parts for the shelf.  These consist of two oak rails at the outer ends and a 1/2" thick piece of Baltic Birch Ply spanning them.  To make a secure joint between rail and plywood we'll cut a deep rabbet on the top of each rail so that most of the rail will set below the plywood.

Gluing up shelfAfter dry fitting to be sure the joints will close up nicely and that the upper faces of the rail and plywood are perfectly flush, we apply glue and clamps.  We cut both the rails and the plywood a bit wide so that we can trim them down to achieve a perfectly flush edge on both sides.

Rough cut door rails and stilesWhile the glue is tacking up on that assembly, we rough out the door stile and rail stock.  This will need to sit for a couple of days before we mill it to finished size, to be sure it will not have any tendency to twist, for that would cause the door to warp and no longer lay flat against the cabinet.


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