Double Cross Pilot Run–Cabinet assembly

by James Brown

Yesterday the cabinet assembly portion of the Double Cross Pilot run was started.  Our cabinets are made of birch plywood, and here you can see how they are cut from a piece of that plywood using a router.  The result is a cabinet with very accurate dimensions, so the fit is much better than if it were cut using table saws and fixtures like most factories use.

After the pieces are all cut, they are glued and stapled.  Notice that all the inside cleats are mounted using routed ‘dado’s’  This technique insures that everything mounts properly, with little chance for gaps or fit problems.

Closeup of the birch plywood:

The radii on the front are added after the assembly is completed, so the fit between sides and top and front pieces can all be very tight glue joints.

Here’s 5 of the pilot run cabinets after assembly:

Tomorrow we’ll finish covering these, and we’ll finish up the final assembly part of the pilot run.  We should get some out tomorrow if all goes well.