Basic base board construction with easy alignment.
Entry posted by Sasquatch
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Well time for this entry which I hope will be of some interest. Please do not take my basic approach as too simple as there is a need for simplicity in regards to such construction.
My choice of material is 1/2" ply wood. This stuff is a great invention as it has built in strength thus no need for bracing and reinforcement.
For sturdiness in the boards a depth in the side rails of around 20% top width should be sufficient thus 1 foot wide boards needs 2 1/2" rails. A 2' wide board requires at least 4" rails.Anything less will sag.
The 3 basic rules of cabinet making are measure everything twice, cut the largest/longest parts first and if at first you don't succeed. Cheat!
Start by making a drawing and a cutting list with number required, rips (cutting along the wood) and cross cuts for each part required.
If you need wood ripped take your cutting list to the DIY store/lumber yard and get them to do it.
Never cut large heavy sheets of material with small machines!
Here are the basic tools needed.
I am using OFB for this step by step and have used it for at least one baseboard in the past!
Start by marking the lenghts out.
If you don't have access to a chop saw.
Clamp two or more bits down with 2 clamps and cut from corner to corner.
Then cut the same but opposite corners and finish off.
Take 1 cross member and mark for two holes to drill for 1/4 inch coach bolts (or thicker if required)
Using two clamps, clamp 3 pieces flush and some scrap down tightly and drill through all three.
Hammer in the coach bolts
Mark the edges like this so not to mix sets up.
One diagonal mark for the first set two for the second etc.
Number them for easy identification
If you require holes for wiring use the same technique
Mark a double thickness on one end of the side rails.
Using a square mark where you want the cross members (avoiding any point motors etc)
If you are a belt and braces man you may wish to screw each joint. Clearance holes and countersink for two screws at each joint and pilot holes in the ends of ply. I can't stress how important this is.
Begin assembly on a clean and clear flat surface by running a bead of glue (using a forefinger to guide the glue bottle) along your marks.
Do this upside down on the base board top.
clamp things together and make sure things are flush and square.
With the first two pieces of the drilled set bolted together clamp in place on the end with glue on the innermost one only.
Remove the outer one to make sure no glue had squeezed out. Now add the third gluing it to the middle piece and linning up those diagonal marks.
This forms the end of the next board. which will line up perfectly.
Use the frame to mark the top side of the top and fix the top down with fine pins and glue on a flat surface.
This fiddle yard serves two layouts and comes appart in minutes using my male-female technique.
The close ups show the electrical connectors well but this type are hard to find.
I will tackle legs in my next blog.
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