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The next task is to cut a rabbet in the
inside back of the outside pieces to secure a 1/4" plywood back. Andrea adds
the rabbeting fence to the table saw. It is a simple piece of plywood with
the area cut away to allow room for the dado blades. And, yes, it is upside
down this time. She wants to make such a shallow cut (3/16") that if she had
used the regular cut away area, the small components would fall into that
gap and make rabbeting difficult and unsafe.
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We were going to untape all the outside pieces, but decided that they were
so well joined together, that rabbeting them in tandem was safe and made
more sense. Using two Grr-rippers in "leap-frog" fashion, Andrea made the rabbeting
a quick and secure operation. I would not have tried this if I had to rely
just on hand holds or the regular push shoe.
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Andrea inspects her rabbets. They are perfect and everything is still intact.
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Normally, I am not a great fan of the quick grip type hand clamps, but they sure came
in handy for this operation. Andrea has folded the outside using the
reinforced tape corners and adds a clamp at each corner to maintain the
squareness.
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With the outside folded and clamped in place on a piece of 1/4" oak plywood,
she can carefully run her pencil in the rabbet and outline the case.
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She uses a speed square to "straighten" her outline.
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She uses the Festool
Trion PS300EQ jigsaw to cut on the lines. This jigsaw set to the straight up
and down cutting action makes following the line very easy and produces a
crisp, clean cut. Just like Gail found when cutting out the clock, the barrel
grip has a good "feel" to it — making it comfortable to guide precisely.
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She test fits the back in the rabbet. It
is a great fit. No trimming is necessary.
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With a little help from the paint program on my PC, I
have "installed" the inside grid that we have to make next. It should be
relatively easy except for the connection to the outside case. I want to
have it firmly fixed but without any brads or nails — although, that sure is
tempting.
The red marks are where Andrea and I will dowel the inside frame to
the outside corner. These corners will have to be glued as a corner first
and then the dowel drilled into the final glued corner.
We have two doweling options: One is with the DowelMax and 1/4"
dowels and the second is to use the WoodRat to make 1/4" mortises and use
floating tenons. Andrea says "let's try them both." That we will
do for next
week's update.
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