Since I am using splines for this project I had to create a groove in the ply-wood to accept the spline.  To do this I used a router bit designed to create a 3/8" grove.  I did this to all 4 edges of the ply-wood.  If you notice in the picture I used the fence on the router table, you may be asking why when there is a guide bushing on the bit?  The reason is because the bit is designed to cut deeper than I wanted it to go.

Next I had to cut the splines themselves.  I used the table saw for this.  THIS IS A DANGEROUS OPERATION I WILL NOT SHOW PICTURES OF THIS.  After the splines were cut they were test fitted to ensure a snug fit.  

The next operation I did was to mill the cherry to size.  This required that it be square up first, because it only came with one straight edge. I then cut the side pieces to width and to length.  Actually I had my son and his friend cut them to length.  The picture to the right is actually my son's friend cutting a spline to length, but it is the same concept.

Now the cherry needs to be milled by butting all the groves where they need to go.  Where to put them?  Well what I did first was to put a matching groove (dado) in it near the top edge to except the splines cut earlier, or should I say my son, Joseph, did it.  I can say I did some too, LOL.  Please take note of the feather board.  A feather board is used to prevent kick back and it helps keep an even pressure on the wood which makes for uniformed depth of the dado (Groove).  A 3/4" dado was cut into the bottom edge of the Cherry.  The 3/4" dado is a blind dado, it does not show from the front or the back of the piece. I also cut a 3/8" dado in the bottom front all the way through in front of the 3/4" dado.  Will explain about that later and I hope you understand when you see the reason for it.

Then I had to mill the Face frame.  I decided to make Dove Tail Joints here.  I must admit that this was the first time making this joint and found it to be a challenge because I don't have the proper jig.  So I had to get creative here.  What I did first was find the center point for each dove tail.  I then measured from the center point to the end of the stock was to be milled.  I then clamped a piece of stock to the work bench to act as a guide.  I clamped the top and bottom "rail" together along with a backer board to prevent rip out and ran it over my router bit.  I repeated this each time for each Dove Tail Joint.  The next thing I had to do was to figure out how I was going to cut the "Tail" portion.  Again this was a real challenge because of the size of the pieces I was dealing with.  If you notice my router table fence has a large opening and the small pieces I was working with could have very easily been "sucked" into that gap.  My solution was to clamp a piece of scrap over the opening (see the picture to the right).  I then took a small "sled" I had made for milling small parts on my table saw and clamped the piece to it.  The piece you see in the picture was my test piece (one of many).  Once I had the fence set in the right place it did not take long at all to mill these piece.

I then cut some 3/4" ply-wood to size to act as a base for the drawers to ride on and dry fitted everything together.  After the dry fit I glued everything together, no mechanical fasteners.

I then built the drawers for each space.  Because I was not, believe it or not, perfect in making my cuts.  I cut and made each drawer for it's specific slot.  Sorry I am not going to get into all of the drawer building here.  

After each drawer was fitted to each of their slots. I milled each of the drawer faces.  To do this I used a Rotary tool with a small router bit.  I also rounded over the drawer sides to prevent injury when reaching into them.  This was also done with the Rotary tool using a simple round over bit.  It was just enough to smooth it and make it safe.

Because the Rotary tool with it's base is so small I had to come up with away to be able to stabilize the unit.  So what I did was cut a piece of scrap to the same height as the drawer sides.  I then place a piece of scrap in between the drawer and the scrap I cut down.  This way the Rotary tool was able to ride along the drawer and the scrap to provide a stable base.  See the picture to the right.

Well this is what it looks like at this stage all glued up.  The next stage is going to be the mirrors.  So stop in again soon and I will have hopefully, completed the project and this article.

Please send questions and comments to me at Messmanswoodworking@cox.net

Putting the groove in

Spline dry fitted.

Sons friend Kevin cutting spline to length

My Son Joseph making a 3/8" dado

Here I am also cutting in a 3/8" dado into the      cherry

Set up for cutting the upper and lower rails

Cutting the receiving part of the Dove Tails

This is the crazy set up I came up with to cut

the tail portion of the Dove Tails

The dry fitting.  No clamps I could not believe it

The completed Dove Tail Joint

The joint between the top ply and the cherry

The set up.

Rounding over the drawer sides.