Project - "Debbie's Kitchen Breakfast Nook"

   I want to rip some 3/4" ply to the widths that I need for each of the benches. I usually do not make wide cuts at the table saw. The Incra TS-III has two sets of stops. The arrow points to the one that is closer to the blade. My fence is usually against this stop when using the table saw. The further stops are for when I use the insert router. Today, I want to use the further stops for making wider cuts. When I installed the Incra TS-III, I carefully aligned the fence and set the stops at both positions so that I could use the further stops for wide cuts — as I ma doing now..
  

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   I make the cut. Note that I am keeping my eyes on the board and the fence. As long as I feed the board smoothly and keep the edge against the fence, I will get a good and safe cut.

    I test fit the top. I have added several finishing touches to these tops. First, I added a 1 1/2" edge on the front and sides so that I could round them over.  I have also added a piano hinge to each bench top and sanded all the pieces. Now I can move to the second part of Debbie's project — the cabinets.

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   I am using 3/4" white melamine chipboard for the cabinet cases. I have ripped all the stock to width, rabbetted the sides to receive the back and am now cutting all the case parts. There are three cabinets in all.
 

    I am lucky to have an accurate eight foot fence extension for the miter saw. I have zeroed it for the blade and can make the many cuts needed with repeatable accuracy.

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        There are a number of ways that I could have constructed the cases of these cabinets. I am using pocket hole joinery simply because I can assemble the units faster, and I do not need to clamp each piece. The pocket holes at the top will not be seen, and the ones on the bottom will be covered over and painted.

    I line up opposing sides so that I can drill the shelf clip holes to match. I don't want the shelves to be slanted.

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   I have used this shelf hole drilling jig for over a dozen years. I am using a 5mm Vix bit. I simply place the bit in the hole and drill a precisely depthed hole. The jig is the Rockler JigIt for shelf drilling.

   Along with the pocket screws, I am using Gorilla Glue. This is the only type adhesive that works well with white melamine stock. A word of caution: use it very sparingly. The squeeze out can be a bear to remove — and that is putting it mildly. I use lacquer thinner to clean up any unwanted glue marks — and my hands.

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      I use one clamp to hold the pieces together.

   As I screw each of the pocket screws, the joint becomes very tight. I am using 1 1/4" washer head screws with coarse threads. The washer head keeps  them from being pulled through the chipboard. The coarse thread is recommended for this material — it get a stronger grip without splitting the core.
   Pictured below is this screw — a picture is worth a thousand words. This screw is perfect for this application. This is a McFeelys product; click here to go there.

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