BUILDING THE PIGEONHOLE UNIT

The pigeonhole unit is made to fit between the tops of the desk and drawer sections of the secretary. Molding can be tacked in place to hide the gap between the two carcases, as shown at left. You can also omit the molding, leaving the pigeonhole unit removable.

 

BUILDING THE PIGEONHOLE UNIT

MAKING THE UNIT

1

BUILDING THE PIGEONHOLE UNIT Rough-cutting the arches

Referring to the anatomy illustration of the pigeonhole unit (page 108), out­line the shape of the arches on a piece of %-inch plywood, cut it out, and smooth the edges to fashion a template that you will use to make a routing jig (step 2). Before assembling the jig, use the tem­plate to outline six copies of the shape on your arch stock. Cut out the arches to within H inch of your cutting lines using the band saw. To keep the blade from binding in the kerfs, make a series of release cuts through the waste, stopping % inch from the lines. Then saw along the waste side of the lines, feeding the work­piece with both hands (right). Make sure that neither hand is in line with the blade.

BUILDING THE PIGEONHOLE UNITBUILDING THE PIGEONHOLE UNIT

2

Shaping the arches

To complete the routing jig, prepare a guide piece with a notch to fit the arch blanks you cut in step 1, and fasten it to the template, centering the notch over the arch outline. Screw two toggle clamps to the guide piece and secure the first blank to the jig. Next, install a top-piloted flush-cutting bit in your router, mount the tool in a table, and adjust the bit height so the pilot bearing will ride against the template. To complete the setup, clamp a picket-shaped pivot bar to the
table in line with, and almost touching, the bit. To trim the arches to final shape, hold the jig with both hands and press the template at one end of the arch pattern against the pivot bar. Then pivot the jig and blank into the bit. Once the tem­plate contacts the pilot bearing, shape the arch by guiding the cutter along it, starting with the bearing pressed against one end of the pattern, riding it along the template, and stopping when it contacts the opposite end (above).

Gluing up the unit

Cut the parts of the pigeonhole unit to size and prepare them for assembly. In the top and bottom, cut dadoes for the dividers and rabbets for the sides; in the middle two dividers, cut dadoes for the drawer supports. Spread glue on the con­tacting surfaces and clamp the assembly securely; reinforce the joints with finishing nails. Make six curved clamping blocks to fit in the middle curves of the arches. When the unit is ready, remove the clamps and apply adhesive to the straight edges of the arches, then clamp them to the unit, using the curved clamping blocks to dis­tribute the pressure squarely (left). Refer­ring to the anatomy (pagel08), make three drawers for the pigeonhole unit, rab­beting the drawer fronts for the sides and dadoing the sides for the backs. Attach a pull to each drawer front.

 

Drawer

support

 

Divider■

 

Clamping

block

 

BUILDING THE PIGEONHOLE UNIT

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