The drawers were designed as a box structure made from five pieces of solid walnut and a base made front hardwood ply veneer. The box was constructed using a simple yet effective rebait joint, cut into the back piece of the drawer, so that if the drawer length had to be altered for any reason, this would provide a certain level of tolerance as a safety measure.
The rebait was drawn onto the walnut, half the thickness was marked out on the perimeter edge of the walnut on all four sides, and a consistent length was marked across the grain from both vertical ends. This was then cut on the band saw, using a jig to support the walnut when cutting into the face of it, to physically cut the rebait.
The two side pieces of the drawer will then slot into the rebait join of the back piece and rest against the shoulder of the join, and the base will slot in against the routed grooves in the drawer sides and back.
The most difficult part of the drawer construction was the front of the drawer, due to its angled nature. This provided multiple challenges, mainly in gluing. However, one suspected problem encountered was that the angle on the front meant that the base of the drawer wouldn’t slot in at the same height from the bottom of the wood piece. This was quickly solved by enlarging the width of the groove on the drawer front – the base will then slot in, but the groove would be at an angle to the base, so it wouldn’t necessarily be a tight fit, however, any gaps would be fulled and packed with gorilla glue. The drawers were asssembled, using gorilla glue as an adhesive, clamped, and left to set and dry. Any glue that was extruded from the joins due to the pressure was wiped away with a wet warm cloth.
The greatest challenge with assembly the drawers correctly, was one that had admittedly not been considered within the design stages of the product; how to glue the drawers together securely without clamping or applying pressure to the angled front. As this slight lack of fore thought came up quite suddenly, it was a matter of thinking on my feet to solve the problem. Therefore, i came up with a jig kind of set up. A large piece of cheap board was screwed to the table and a piece of 4×4 timber blank was screwed on top of the ply board, running parallel along the straight edge. Another corresponding piece of 4×4 was screwed, parallel to the board, with a set distance between the two. The drawer would then be placed against the front bar of 4×4, a wide (tall) piece of pine timber would be placed on it’s side to provide a tall vertical barrier that would push into the drawer and act as a clamp. This pressure was exerted onto the drawer through the timber by a thick wedge of timber, cut at an angle, that would fit and could be hammered between the tall piece of timber and the 4×4 blank bar that ran along the back side of the board. The drawer would be held together by g-clamps, exerting pressure from the sides of the drawers, to allow for adjustment of the drawers – particularly to make sure that the drawer front bottom edge was flush to the table top, and was not extruding past the five degree cut angle on the side of the drawers, which would affect how the false drawer front would sit flush with the angle cut on the front edge of the side pieces.