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  1. #1
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    Default WIP Beginner mistake - help!

    I hope I have this in the correct forum.
    This is only my second WW project so please be kind.
    I started off making something simple and as I progressed I thought; wouldn't it be better if I changed .....
    Oh now wouldn't it be better if I added.....
    and now I could....

    So that was probably my first rookie mistake but it's a hobby so that is OK.

    I thought I'd make 2 low shelves to support and raise the computer monitors on my desk in the office.
    At first I thought I'd knock something together quick with pocket hole joinery.
    Then I decided to add a small drawer on one end and to make the two shelves mirrors rather than the same. Then I decided to space the supports differently so the 2 are unique. That was OK. No worries.

    My first rookie mistake was not realising that things move when screwing pocket holes. So the first one has legs that are not quite square. For the second one I got some corner clamps from Ebay first and this 2nd one is OK.

    I also decided to experiment with pocket hole screws going the 'wrong' way to better hide some of the holes on the 2nd one. Risky but that was mostly OK.

    I liked how my end drawers turned out. I only wish I had not sanded the pine top with a machine because now they are not quite square. Never mind. Only one way to learn somethings.

    Then I thought the pocket holes looked more ugly than I had expected. I didn't really fancy cutting dowels for all those holes and more importantly it still would have been obvious. I decided to add more drawers partly to cover up the holes and for the experience. Plus hopefully it will make them more useful. So now these are more like some furniture than a basic shelf. Each will have 3 small drawers for pens and small items.
    20170608_174352.jpg

    The problem with that was that the frame/legs on one are not quite square.
    So on one of these stands the two new drawers are not square with the front.
    Here is one of the new drawers as it is now, before I put the faceplate on. Excuse the distorted perspective from the camera angle.
    20170609_104350.jpg

    Of the two out of alignment, this is the worse one. It is about 3 or 4mm out:

    Rot20170609_104318.jpg

    Last night I started to sand it down a bit by hand. However that is way too slow and worse, I have already inadvertently started to create a curve and loose the flatness at the front. The front part of the draw is MDF, sides and bottom are ply. The faceplate is some recycled hardwood.

    If I use my Random Orbital Sander on it I am certain to round it out of flat. I don't have a benchtop sanding machine. Or a jointer. I don't think I can hand plane MDF - or can I?
    I suppose I could mount some sandpaper on a board and manually work it down on one end. Borrring!!!! (+ MDF dust everywhere, bugger).

    My 1st question is, should I sand this down to make it align with the front before I fix the faceplate?
    Or
    Should I leave it and stick on the faceplate then either live with it or see what else can be done?

    If I do sand it down first, then how should I do that with my limited tools?

    Bonus question: is this the perfect excuse to buy a benchtop sanding machine for next time?

    Thanks in advance.
    Dave.

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  3. #2
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    Default

    There are a number of options depending on whether the drawer is square, out of square but a parallelogram or if one side is longer than the other. Not knowing this, I suggest the following.
    If that was mine and I didn't want to remake anything at all, I would mark the misalignment on the top edge and bottom edge of the front of the drawer and use a plane to correct. As you have endgrain at either end, I would clamp an a sacrificial piece of wood at either end, or the end the plane finishes at, to prevent tear out.

  4. #3
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    Hi dave
    by "faceplate" do you mean taht the drawers will have a false front? and you have yet to fit the fronts?

    provided the drawer goes all the way inside the drawer box, the easiest way to hide the feature is to pack out the false front
    regards from Alberta, Canada

    ian

  5. #4
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    Default

    Thanks Lappa.
    You pose a good question. I have assumed that the frame is out of square but I haven't measured the draw to see if the problem is with the draw.
    I'm not really considering remaking the draw unless that is going to be less work. I'd rather get the job finished and chalk it up to experience. It's a question of maintaining momentum. I've already let this project grow and grow when I should have been doing more basic things first.

    I just measured it and it is less than 3mm. (Not 4 as I had imagined).

    I don't have a proper vice or solid workbench, so planning anything is problematic. I could use my cheap electric planner on it I suppose. Is that a good idea? The plywood ends are only butt jointed with glue. I worry what a plane might do to that joint.

  6. #5
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    Quote Originally Posted by ian View Post
    Hi dave
    by "faceplate" do you mean that the drawers will have a false front? and you have yet to fit the fronts?

    provided the drawer goes all the way inside the drawer box, the easiest way to hide the feature is to pack out the false front

    Yes that is what I mean. There will be a front plate made of nice hardwood. You can see I have already done this on the end drawers but I am yet to prepare and fit them to the new drawers.
    I made these drawers approx 5mm short of the cavity so they don't go all the way to the end stop at the back. I could pack the front out, no problem.

    Thanks. That sounds like the easiest way.

    Sorry for the stupid question but I don't know what to use for packing. How do I make a wedge that thin?
    I have a nice blade on my SCMS but I'm not sure how I would hold the scrap to make such a cut along the grain. I would have to figure out some jig to hold it in place.
    I guess I'll experiment with my triton workcentre and see if I can rip something on that.

    Or do I put any old packing in there on one end and not worry about a gap behind the faceplate? Maybe it's time to discover wood filler?

  7. #6
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    For packing you can use either some scraps of wood, or if you like buy some window packers and adapt.
    I would be using some off cuts, cut down to size.

  8. #7
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    Quote Originally Posted by Handyjack View Post
    For packing you can use either some scraps of wood, or if you like buy some window packers and adapt.
    I would be using some off cuts, cut down to size.
    Sorry I didn't express myself well.
    The draw is roughly 30+cm wide. So I need a wedge 2.7mm to zero that is 300mm long approx x 50mm high approx. I'm wondering how to cut such a thin wedge.
    I don't have a proper table saw.

    I'm suffering from fatigue today so I'll have a go on this over the weekend.

  9. #8
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    If the photo you put in the first post is with the drawer pushed all the way back, then padding the front panel will have it sticking out too far from the front of the cabinet. If you push the drawer all the way back and one end is level with the front of the cabinet and the other further in, then padding out the front panel will work.

  10. #9
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    Quote Originally Posted by Lappa View Post
    If you push the drawer all the way back and one end is level with the front of the cabinet and the other further in, then padding out the front panel will work.
    Yes I understand. I have pulled the draw forward to show the misalignment to you guys. One thing I got right was to make all the drawers less deep than the cavity they sit in. This just seemed initiatively the correct thing to do. Now it might pay off.

    I was planning to get out to the shed tonight and work on it. But I feel a bit shattered so rather than botch it, I'll leave it until tomorrow.

    Cheers Dave.


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  11. #10
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    Quote Originally Posted by DaveVman View Post
    Sorry I didn't express myself well.
    The draw is roughly 30+cm wide. So I need a wedge 2.7mm to zero that is 300mm long approx x 50mm high approx. I'm wondering how to cut such a thin wedge.
    I don't have a proper table saw.

    I'm suffering from fatigue today so I'll have a go on this over the weekend.
    No, you do not need a wedge that big. A piece of scrap about 2.5 thick and no more than about 50 x 25mm should do you. Just have it in the right place so when the face plate is attached it is flush. Just make sure a fastener is either through it or close enough not to distort the face plate

    I do not have a table saw either but recon I could cut a wedge you described with a circular saw and guide (or track). If the piece cut was longer but still have the same angles, you can always cut it smaller.

    As you are finding out, sometimes there is more that one way to achieve the same result.

  12. #11
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    With the end drawers I only glued the faceplate on. The drawers are small. It's difficult to get inside there to pre drill.
    Also I don't know how to hold a faceplate in just the right spot unless the draw is sitting in position on its runners. Which means I can't access the inside of the draw during glue up.
    Mmmm
    Maybe I could use double sided tape to hold it. Fix the screws in position. Disassemble it. Then glue and screw it. Is that how it's done?

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  13. #12
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    Hi DaveVman
    For mounting the front with no access to clamp it in place drill you're handle holes in the front only then screw the front to the draw box through them take it out and fit mounting screws from the inside then remove the one's through the handle holes and drill right through to fit handle's.
    Regards Rod.
    Rod Gilbert.

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