ARTICLE: Dream Island
Contents
1. STEP 3 Form the groove by cutting a notch in the center strip see art right Double Side T Sacrificial B Backer VAL A yp y STEP 4 Carefully align the recesses and the top ends of the strips as you glue the decorative face back together WOW Wo W O RIKI l A C BUMA GJA 2 IUN JB a C O M 51 END ASSEMBLY VIEW Se en es Assembled Leg Ul Inner Stile Ledge 34 x 1 4 x 34 nd Apron oe St BG x6 x 34 o x3 x17 34 x 4 x 292 1 Pocket Screw Upper Rail 34 x 24 x 292 End Panel Stop mM x Vo x length to fit Stile 34 x 24 a Y4 grooves Y4 deep Lower Rail End Panel Y4 ply x 13 x 1644 1 4 Pocket Screw END ASSEMBLIES The frame and panel end assemblies are just as important to the furniture like appearance of this island as the legs are And just like the legs they feature some unusual construction The frames themselves are fairly standard they re solid wood pieces that are assem bled with stub tenon and groove joinery End Assembly View above What makes these assemblies unique is that the groove doesn t house the panel as you might expect Rather it accepts a panel stop which in turn holds the panel This simple design twist adds one more layer of detail or depth to the assembly to make it look more like fine furniture and2. BockPonel 1 4 30 39 Ook Plywood Vertical Divider 1 4 23 30 Oak Plywood Fixed Shelf Fixed Shelf Edging ya 39 Ook ya 39 Ook ya 29 Ook 39 Ook 29a 39 Oak Plywood w 342 342 ya 23 Ok A 292 162 Y G Front Bottom Edging Back Bottom Edging J Vertical Divider Edging Stiffeners Finish Panel Adjustable Shelf Decorative Leg Faces lain Leg Faces eu 1 ET 1 EN EA EA 1 4 12 tiles 2 2 2 EJ 16 4 E Ey 4 1 oa nner Stiles Upper Rails Lower Rails j Panel Stops End Panels Ledges WA We 634 End Aprons X Y Hinge Jamb Z FrontAapron 1 Spacers E Ea G mn EE Ea K L M N ol Ea KJ R E3 Ea U X EA YM y y y A y y y y y y A A 4 4 4 4 29 to fit 16 34 Ook 34 34 A 3 23 634 WWW WORKBENCHMAGAZINE COM BB Trim Strips Fron Back 2 9 1 45 Ook CC Trim Strips End 2 9 40 Ook DD Top Door Rois 2 2 1 Ook EE Bottom Door Rais 2 4 11 FF Doorsties 4 2 22 Ook GG Panel Stops 8 w Y tofit Ook HH Door Panels 2 a 85 1614 Oak Plywood Wood Pegs 8 w Ook JI Shallow Drawer Fr Bk 4 Yo 5 4 8 Ook KK Deep Drower Fr Bk 4 Yo 7 8 Ook LL hallow Drawer Sides 4 Yo 5 4 2256 Ook MM Deep
3. Front Bottom Edging 34 x 24 x 39 bottom right side fixed shelf STEP 3 Attach back amp left side with glue amp screws Vertical Divider STEP 4 Glue edging to Edging vertical divider see page 22 for clamping technique Stiffener Detail Pocket Ze Pocket A ra Screw 8 x 1 4 Fh Woodscrew 1 Drill 346 pilot holes for attaching countertop STEP 7 Make adjustable shelf and set aside STEP 6 Glue on Finish Co T Vertical Divider STEP 1 Apply hardwood edging to fixed shelf and bottom panel see Edging Detail f oi za saa Sse Z ii a J i EESE i Fixed Shelf Sia isthe oi a IXe weft E ae Fee s Es R A sie oe Mee i Y I n a A aTe vi reel 1 SOS errs era i a a ee Weir Vy pint Iv gt 1 1 Ve om i vi ia T g ae D f STEP 2 Assemble 8 x 1 4 Fh Woodscrew 1 TARRE f Teo aea 7 1 1 1 i TN 1 Ior 7 OE 1 J amp vertical divider with glue amp screws Notch Detail Vertical Divider A STEP 5 Attach the hardwood stiffeners with 1 pocket screws lt gt Finigh Panel 4 plywood NOTE Adjustable Shelf Back ae of Yo x 934 x 38 case snown 49 FOUR EASY PIECES The Craftsman inspired furniture style legs are clearly the most striking feature of this kitchen island That s due to the square recesses and long decorative groove that adorn one face of each leg But ju
4. Vertical Divider Edging 34 x 2 x 29 Stopped dado for fixed shelf with solid wood edging and that s when those unusual details I men tioned start showing up Case Panels To get started cut the panels A through F to size Now cut a notch on the top corner of the vertical divider Notch Detail page 49 This notch will accept a stift ener a little later Simply lay out the notch and cut it with a handsaw The next step 1s cutting the joinery and this is where you find the first of those unusual details Notice that the case sides have dif ferent letter designations B C even 1 B 34 ply x 2234 o Ea es Sheli SRE x 28 ging ii a 4 x 34 Oe x 28 Right Side 34 ply x 34 x 302 ee i d aie ae d Le i l Botiom Front Bottom Edging 34 x 24 x 39 Dado for fixed shelf _ 2314 34 plywood PARTS VIEWS io 23 4 yy holes 30 Yo deep for shelf pins Yo eS x Rabbets for bottom 34 48 WORKBENCH though they have identical dimen sions What differentiates these parts is the joinery The right side panel B has a dado for the fixed shelf and the left side C does not It s an impor tant detail that s easy to overlook With that in mind you can get started making the joinery The size of the plywood panels and the fact that some of these joints are stopped pretty much di
5. cut a groove in the drawer box pieces to accept the plywood bottom Now cut the bottom NN to fit and glue and clamp the drawer box together Next cut the false fronts OO PP to size and then screw them to the boxes with the bottom edges flush Now drill each drawer for the pulls and install the hardware Finally install the drawer pulls and mount the drawers in the island with full extension drawer glides A Next use a chisel and cut A Now cut with the grain to across the grain to establish the square off the remaining edges of first edge of the mortise By cutting the mortise The intersecting across the grain first you will edges of the mortise have A Finish up by gluing a 3 8 x 3 g peg into the prevent the the wood from split already been established so this mortise Leave the peg slightly proud and then ting during the next few cuts part of the cut will go smoothly sand it flush with the surface after the glue dries 3 wy n 4 WWW WORKBENCHMAGAZINE COM 55 COUNTERTOP ASSEMBLY Countertop Substrate 1 o MDF x 43 x 48 NOTE Make substrate from two pieces of 34 MDF 56 ProFire Plastic Laminate Electrical Outlets Gas Grill Black Pipe Coupling Flexible Gas Line COUNTERTOP Installing the nearly complete kitchen island is more than just setting it in place The island will also have to be
6. router techniques see page 50 Decorative Pegs give the appearance of pinned tenons The ProFire Indoor Gas Grill we used requires a range hood with a 1500 34y cfm blower We installed a Broan NuTone Range Hood model 630004EX with a Rangemaster 1500 cfm exterior blower see Buyer s Guide on page 57 End Assembly features unique frame and panel construction that contributes to the island s furniture style appearance see page 53 Y Simple table saw and router tech niques make the shallow square recesses decorative groove and wrap around trim easy to create CASE ASSEMBLY NOTE Cut all dadoes rabbets and grooves 1 4 deep width to fit CONSTRUCTION Beneath the decorative legs applied molding and frame and panel end assemblies this kitchen island is a nearly standard plywood case Case Assembly I say nearly standard because there are a few unusual details We ll come to those soon enough but first let s look at the the basic case The case consists of a bottom A two sides B C a back D a vertical divider E and a fixed shelf F All of these parts are cut from 4 ply wood and joined with dadoes rabbets grooves and woodscrews The plywood edges get covered Left Side Vertical 34 ply x 34 Divider x 30 Tx fet ple xa0 ee rei i 3 4 ply x 34 x 3914 ie gt
7. case you need to add a couple spacers X As the name implies they fill the space between the end assemblies and the case and also create a large glue surface for attaching the end assemblies to the case Spacer Detail Cut these pieces to fit between the legs and glue and screw them to the end assemblies Now you can attach the end assemblies to the case You ll need to jack up the case so it s flush at the top with the end assemblies Installation Detail Spread glue on the spacers and then clamp them to the end assemblies Next drive pocket screws from the stiffeners and into the end assemblies Installation Detail Applied Details There are just a few details left to complete the case First is a hinge jamb Y This piece ensures the proper clear ance between the door and side of the case so the hinges will be able to swing fully open Notice that this piece has a notch cut in it to go around the fixed shelf see the Hinge Jamb Detail below Next are the front and back apron pieces Z AA These are simply cut lt 4 To protect the panel from glue squeeze out run masking tape 1 4 in from the edges of the panel before gluing it in place to fit and then they are pocket screwed to the case sides Finally add the decorative trim strips BB CC that wrap around the case First cut a notch in both ends of each trim strip to fit into the dadoes in the legs Then miter the piece
8. comes As for the vertical divider edging what makes this part unusual is a notch in the upper front corner Notch Detail This accommodates an apron that gets attached later Assemble the Case The Illustrations at right should make the assembly sequence clear But there are a couple of points to take note of First the vertical divider edging presents a bit of a clamping challenge Fortunately we worked out a simple tip for applying this piece page 22 Next are the hardwood stiffeners K These need to be pre drilled with two pocket holes Stiffener Detail below One hole is used to connect the stiffener to the case The other helps secure the legs to the assembly later Then there a 1 4 plywood finish panel L that s glued to the back of the case This panel not only hides the screws in the back it also let us select an attractive grain pattern for this highly visible area of the island However clamping this panel would be tricky at best so we used con struction adhesive to create a strong bond There are some helpful tips for this process on page 22 The final piece of the case is an adjustable shelf M The shelf is 1 thick so it can support heavy appli ances or books without sagging Simply cut the shelf to size from solid wood and set it aside for now WWW WORKBENCHMAGAZINE COM ASSEMBLING THE CASE Edging Detail Pocket Hole drilled from Back Bottom Edging 1 x 2 4 x 39
9. tape so any excess glue winds up on the tape Photo right By the way be sure you re masking the good or show face of the panel 4 plywood only has one such face Ledge and Apron Now it s time to add a decorative ledge V and end apron W to the assembly Cut these pieces to size from 4 thick hardwood and then drill pocket holes in them as shown in the Assembly View These pocket holes will be used to join the end assembly to the legs Once these holes are drilled glue the ledge and apron to the frame and panel assembly Assembly Connecting the com pleted assemblies and legs can be chal lenging because you have to manage fairly large units and keep them aligned And speaking of alignment note how the end assemblies are set back 3 4 from the face of the leg Leg Mount Detail This is yet another detail that helps create a furniture style look WORKBENCH O OCTOBER 2005 To assemble these pieces start by placing the legs outside face down on a large flat surface Then position the end assembly also face down between the legs Support the assembly with some 4 scrap pieces This will give you the perfect setback from the face of the legs to the face of the end assembly Align the parts so the tops of the legs are flush with the top of the end assembly Install the pocket screws to secure the whole works Add the Spacers Before the end assem blies are ready to be attached to the
10. Drawer Sides 4 Yo 7 2256 Ook NN Drover Bottoms 4 1 8 22 Oak Plywood OO Shall Drover Fase Frons 2 9 5 95 Ook PP Deep Drawer Fake Frons 2 24 8 9 Ook QQ Countertop Subsite 2 4 43 48 MOF e 4 Blum 55809 120 Inset Clip Top Hinge e 8 Blum 34876 22 White Drawer Slide 8 Smedbo SME 04356 Drawer Door Pulls 53 8 x 1 Fh Woodscrews 28 1 Pocket Screws 4 8 x 13 4 Fh Woodscrews 6 Metal L brackets 57
11. a stop block Fig 4 OCTOBER 2005 WORKBENCH gauge and stop block to ensure con sistent results when making these cuts Routing the Groove Next comes the decorative groove It s formed by cutting a long notch in the center strip Most of this mate rial will be removed on the router table but it s best to first establish the shoulders of the notch on the table saw Fig 1 Once that s done remove the stop block and make several more passes to widen the cuts to about 2 This will make it easier to start the cut on the router table To do that mount a straight bit in the router table Then tape the strip to a sacrificial backer board for sup port and to give yourself a safe hand hold Fig 2 Now make a sideways plunge cut into the bit to remove the remaining waste material Fig 3 Reassembling the Face Now reassemble the strips into a single face First ensure that the strips are back in their original group Then spread glue on the mating edges and align the recesses as you clamp the assembly After the glue dries assemble each leg as shown below MAKING DECORATIVE lt lt pneu LEG FACES Aa a a CUTTING THE GROOVE STEP 1 Rip each NOTE ee e decorative face Each decorative leg lt into five strips face starts as a p a ee pax SUF 36 A eee blank ION STEP 2 Yo Cut Yo dadoes V4 on deep to Yo create square recesses
12. ctates that you use a handheld router and a straight bit to make the joints Clamp a straightedge to the workpiece to guide the base of the router and use some wood scraps as stop blocks when routing the stopped dadoes Hardwood Edging With the panels cut to size and the joinery completed you re ready to add hard wood edging And once again we encounter some of those details The four pieces we re dealing with here are the fixed shelf edging G the front and back bottom edging H D and the vertical divider edging J Of these only the fixed shelf edging is what you might think of as typical It s cut to match the shelf in both thick ness and width and then applied with glue and clamps Groove A for back Stopped dado 10 for divider 34 _V E Stopped groove 30 for fixed shelf _V p 392 _ OCTOBER 2005 The bottom edging pieces are a little more involved First of all notice in the Edging Detail right that these pieces stop 4 shy of the panel edge This is because of the way the legs interlock with this panel A second important point is that these edging pieces are not the same thickness The edging on the back edge of the panel is thicker so it will match an adjustable shelf that you ll make later on The final detail to be aware of with these edging pieces is a pocket hole that must be drilled in each end This will be used to attach the legs when the time
13. d into three of the box sides but not into the removable side Custom Countertop Building a custom coun tertop for this island was an absolute necessity There s no way we could find a pre made version that would COUNTERTOP TOP VIEW _ i 43 1934 WORKBENCH O OCTOBER 2005 KITCHEN BUYER S GUIDE ProFire Indoor Grill Dvorson s Food Service 877 386 7766 Dvorsons com Range Hood Broan NuTone 800 558 1711 Broan com Blum be large enough or provide the perfect complement to the look of the island The easy choice was to fabricate our own countertop using an MDF substrate and plastic laminate Countertop Assembly The technique couldn t be much easier One unexpected bonus is how affordable this material turned out to be compared to other popular countertop materials about 5 a square foot for laminate versus as much as 90 a square foot for solid surface material The fundamentals of building your own laminate countertop and then cutting an opening for a sink or in this case a grill are covered in the article on page 58 Part Qty T WwW L A Cose Botim 1 4 34 392 Oak Plywood Drawer Door Pulls Smedbo Cabinet Hardware 866 695 6627 MyKnobs com Cup Hinges 866 344 6437 BlumHinges com Drawer Slides Blum 800 857 8721 CabinetParts com Plastic Laminate Formica 800 367 6422 Formica com There is one important detail in this ver sion that d
14. entered 120 Inset On Rail Clip Top Hinge Door Stile 34 x Iy x 2234 o i Door Panel sy Y4 ply x 8 x 164 5 W Brushed Nickel Pull n m x Yo x Wood Peg Bottom Door Rail 34 x 3 x14 34 x 4 x 114 There was a time when wood pegs were used to add even more strength to a mortise and tenon joint With today s adhesives that extra step isn t really necessary Nonetheless the pegs still make a nice decorative element But since they are only decorative there s no need to extend the peg all the way through the workpiece Rather by drilling a shallow hole and then chiseling it square you can create a mortise to accept a short peg that looks 9 like the real thing but requires a lot less work And by having the end grain of the peg exposed it will con trast with the frame pieces when you apply a finish The Photo sequence will walk you through the rest of the process 54 DOORS amp DRAWERS T a A ji Song 4 YO OCHRV VYVVY NINN CY ga SO fh ty l OC wD ee Noes IRA TTT NA U p E n i N s These doors share the frame and panel look of the end assemblies and require some of the same techniques Door Construction The difference in the doors however is joinery Here the rails and stiles are joined with mor tise and tenon joints for extra strength Door Frames Get started building the doo
15. esses that adorn the leg faces are created by cutting dadoes in the wide inner strips Use a miter ASSEMBLING THE FOUR PIECE LEGS The four piece legs are assembled with miter joints to prevent the edge grain from showing It s important when assembling the legs that all four faces are the same width Ideally the decorative faces you ve already made are 3 wide If not simply rip the three plain faces to match Once you ve ensured that all the leg faces are the same width the next step is to rip a bevel on both edges of each face in preparation for assembly Start by tilting the saw blade to 45 Then position the fence so you re just cutting away a wedge from the edge of the board without making the face any narrower Fig 1 You may want to perfect this setup on a scrap piece before moving on to the actual leg parts To assemble the legs lay the faces flat on pieces of tape Spread glue on the mating edges Then roll the leg faces together into a single post and secure them with the tape Fig 2 After the glue dries the next step is to trim the legs to length 34 2 Measure down from the top of the leg to establish the cut line then trim them as shown in Figure 3 Finally mount a dado blade in your table saw to make the final cut in the legs This dado will accept a trim strip that gets attached later in the island construction Cut the dado all the way around the leg using the rip fence as
16. et started Decorative Faces As I men tioned each decorative face will be ripped into strips five to be exact so we can cut and rout the decorative elements in those individual strips That means we need to account for the waste that s lost when we rip each blank apart So to get started you ll need four face blanks that are 3 5 wide These should also be extra long 36 or so They ll be cut to fin ished length after the leg is assembled When you have the four blanks ready to go you need to mark them in such a way that you ll easily be able to reassemble the strips correctly If the strips get mixed up during this process you could wind up with mis matched grain An easy way to pre vent that is to mark one end of each blank with a different color of marker Now you re ready to rip the blanks into strips Illustrations page 51 This requires a couple different table saw setups First position the rip fence g from the blade Cut the first strip from the blank then turn the board end for end and rip a strip from the opposite edge Repeat this process for each blank Now reposition the fence to cut a 2 wide strip and use the same process as before to cut the two inner strips The final cut you make also forms the 4 wide center strip Take a moment now and make sure all the strips are grouped with their matching parts before moving on to the next step Dadoing the Details The four square rec
17. iffers just slightly however In this case the substrate is made of two full layers of MDF instead of one full layer on top and a series of cleats underneath We wanted the extra strength that comes from two full layers of substrate to help support the weight of the grill Attaching the Countertop After you ve cut the opening for the grill it s time to attach the countertop to the island Position it on the island and then check to ensure that it s sitting square and centered Once you re satisfied with the position of the countertop I recommend clamping it MATERIALS amp HARDWARE Material Back Apron Faucet Sink Kohler 800 456 4537 Kohler com Countertop John Boos 217 347 7701 JohnBoos com temporarily so it doesn t shift while you re attaching it permanently As for attaching the countertop you predrilled holes in the stiffeners as you were building the case so you can simply drive woodscrews at those locations to secure the top All that s left is to install the grill And the instructions that came with it are the best source as to how that s done That completes your dream island and part one of this kitchen remodel In the next issue we ll detail the matching cabinets an undermount sink and butcher block coun tertops to complete the makeover Material T W L al a en 39 Jok B RightSide 1 4 34 30 Ouk Plywood C leftSide 1 4 34 30 Ouk Plywood D
18. less like another ordinary cabinet Frame First To get started on the assembly cut the stiles P inner stile Q and rails R S from 4 thick hardwood Next cut a groove in the inside edge of each of the frame pieces in both edges of the center stile to accept the panel stop 52 that will support the 4 plywood panels Then cut stub tenons on the ends of the rails and the center stile to fit into these grooves Stub Tenon Detail above Now it s time to assemble the frame Be sure to make alignment marks to posi tion the center stile as you glue and clamp the frame together Panel Stops With the frames assem bled you re ready to add the panel stops T Besides providing a way to attach the panels the stops serve another purpose Notice how they add extra depth and dimension to the end assemblies in the Photo on page 46 To make the stops plane some stock to thickness to fit snugly into the grooves Then rip the stops to width cut them to length and glue them into the grooves Stop Detail End Panels Next measure the opening in the frame and cut the plywood end panels U to fit Before gluing the panels into the frames take a minute to NOTE Back face of assembly shown if ut H i i thes f a ri i Hi ti i ui ia out eal i ith a i i i ail i i 1 Stub Tenon Detail V4 stub tenon Y4 long 14 Pocket Screw Decorative Face mask the panel with
19. practical ideas for your home workbenc Thank You You have successfully downloaded your document from Workbenchmagazine com Below are some tips for Trouble Free Printing 1 Clear printer memory If you are unable to print this document turn off your printer for at least 15 seconds and try again 2 Print two or three pages at a time If clearing the printer memory didn t help try printing only two or three pages at one time rather than sending the entire Tile 3 If a document is required to be at an accurate scale set the page scaling option to none in your printer settings 4 Get advanced printer help Visit Adobe Support for instructions in troubleshooting common printer problems http www adobe com support techdocs 316508 htm s we took an inven tory of the must haves for our kitchen island we didn t get any further than the first item on the list an indoor grill before we knew for certain that no ordinary island would do Photo left Mounting a gas grill in what is essentially a cabinet is no small thing after all But we didn t want the island to be reduced to nothing more than a place to house this unique kitchen appliance We also wanted to include additional storage for everything from grilling utensils to our favorite cookbooks And of course the island had to look like it belonged in a kitchen Fitting the Grill As you look over the Construc
20. rs by cutting the rails DD EE and stiles FF to size Now cut the tenons and mortises in these pieces To cut the mortises either use a mortising machine or drill out the rough shape with a Forstner bit and then chisel them to final size Mortise Detail The tenons are easy to make with a dado blade on the table saw Tenon Detail Next cut the groove in the frame pieces for the panel stop You ll want to do this on the router table so you can stop the grooves in the mortises Use stop blocks on the router table fence to start and stop this cut Then assemble the door frames using glue and clamps Lower Mortise Detail Lower Tenon Detail NOTE Upper mortise is identical except it is 114 long NOTE Upper tenon is identical except it is 1 2 wide ATo add the decorative wood pegs start by using a 3 g Forstner bit mounted in the drill press to drill a 4 deep hole in the door stile WORKBENCH O OCTOBER 2005 Panel Stops The plywood panels in these doors DRAWER CONSTRUCTION GJ just like the panels in the end assemblies are held in the NN ier Back frames with panel stops GG Just as before plane these ee Drawer Bonom M x 54 x 8 to thickness and cut them to fit Then glue and clamp 8 x 4 x 83 x 22 2 Fh Woodscrew them into the grooves in the door frame Now measure the opening in each door and cut a plywood panel HH to size Once again u
21. s to length and glue and clamp them in place END PANEL amp TRIM ASSEMBLY 1 Pocket Pocket Hole amp 14 Pocket Back Apron End Trim Strip Hole Screw 34 x 634 D 34 x 1 Front Apron x 4014 prey Fx 6 D 8 14 deep WWW WORKBENCHMAGAZINE COM Spacer Detail Front View ay Upper Front Back Spacer Trim Strip 4 x 1 Y x 452 aa ae Ne Hinge Jamb 4 x 35 x 23 1 ae ria 1 C ioe a i 4 i my cL I 1 i 5 1 ty ra li 1 i li I 1i 1 1 one iit i fa we 1 1 gt i Wt y t I ied LF ia 1 too ot 8 a e E i ii 1 4 rela ot Tae a 1 1 I 3 1 E r Ce A i o ee e te ot 1 a Dy Hi i eee al ov lt Tae Tes 1 i s i y a ne soe A yt Y PAN i 5 i P ORA i noe ii fea Pa en meta z V i Woy 1 in ne f ir a i smi ia A 1 Gan i 1 it dea a a 1 Vy pode 1 i a vil a Be vi Wiii 1 1 s IL i iG 1 i ee 1 Mt nd Lin ie DR a 1 im Wo x it 1 L i ti ca na e 1 1 less 4 1 K 1 J ENI 1 ti 1 i pi ll 1 li cni v AN i i v R 1 1 i val y 1 1 Woodscrew NOTE Use scrap pieces to elevate case so it s flush with top edge of end assemblies Lower Spacer 34 x 3 x 34 End Assembly TRIM STRIP PART VIEW Lower Spacer j WANS Lo Ya WRN all 53 DOOR CONSTRUCTION Top Door Rail 4 x 22 x 11 C
22. se masking Drawer Side i tape to keep excess glue off the plywood panel 2 x 34 x 22 2 Decorative Pegs To add a bit more Craftsman o flavor these doors are accented with decorative wood Brushed pegs II at the corners The four step process for this Nickel Pull D l L a z As j f is shown in the Sidebar below centered on D f 7 y y Vy d f A x V4 rawer front JD f al Hardware The completed doors are now ready lk y a Re groove 14 from N 4 2 ae ob for hardware which amounts to a couple of cup hinges bottom edge and a door pull Drill and mount those pieces according a y to the dimensions in the Door Construction Illustration 2 ae ir mG EnS Full Extension on page 54 2 Drawer Slide Dovetailed Drawers Now you re ready to build the drawers Drawer Construction Illustration These are standard dovetailed boxes with a false front a a Start by cutting the drawer fronts backs JJ KK seca A o and sides LL MM to size Then lay out the dovetails i according to the dimensions in the Dovetail Detail Cut 09 False Front NOTE Shallow drawer shown 34 x 594 x 9 See materials list on page 57 the dovetails with a handheld router and a half blind for dimensions of large drawers dovetail jig For more information on routing half Dovetail Detail blind dovetails see the article in the Online Extras sec tion at WorkbenchMagazine com After routing the dovetails
23. st as interesting as the look of these details is the technique used to create them They re not hand cut as it may appear but rather made using a combination of table saw and router table techniques That s possible because each leg is actually made from four boards rather than a single thick blank By ripping one of these boards into thin strips it s simple to cut or rout the decorative details Then the strips get glued back together to create the finished face But that s only one reason to build legs in this manner It also creates a LEG ASSEMBLY Decorative Leg Face 3 W 3 341 W NOTE rat a Finished ae leg is 3 2 square square by y i 34 long 4 peep I 5 Plain Leg Face 4 x au x 3414 Y4 wide groove 3 4 dado lt 14 deep a cut around Ti all four sides of leg ae 50 TEONE much more stable leg than a single thick board would provided you could even find stock large enough to make these legs And in the end you actually wind up using less material this way than if you tried to work with a solid piece of hardwood So now that we know the advan tages of four piece legs lets get started making them Just to clarify each of the four legs is made up of one decorative face N and three plain faces O see Leg Assembly below The decorative faces are where we are going to g
24. th how close the case parts are to the grill That allowed us to really maximize the space Furniture Styling Technical issues aside another priority for this island was to create a furniture like appearance that could be carried to the other kitchen cabinets To that end we treated the island to a set of Craftsman inspired legs that would look just as good on a living room piece as they do here Photo right The island is further embellished with frame and panel end assem blies and applied molding The cab inet doors are built using genuine mortise and tenon joinery and are adorned with wood pegs And of course the drawers are dovetailed together so they re on par with all the other fine details of the island Wood selection was another important choice We carefully selected quartersawn red oak for the solid wood pieces and looked for the straightest grain we could find when shopping for plywood Naturally not just any countertop would do So we built our own We used time tested plastic laminate over an MDF substrate to create the per fect countertop for this island Over the next few pages we ll walk you through the construction of this kitchen showpiece From the basic case to the decorative legs and all the way through the custom countertop the step by step instruc tions begin on the next page WWW WORKBENCHMAGAZINE COM 4 Piece Legs with Craftsman style details are built using simple table saw and
25. tion Details on the next page you ll see that this kitchen island is a bit unorthodox in the way it s compartmentalized By dividing the island in this manner we were able to create a separate compart ment for the grill and still make use of the rest of the cabinet for a bank of drawers some undercounter storage and even a bookshelf on the backside of the island Of course the design of the island depends on using this particular grill Specifically this model from ProFire Buyer s Guide page 57 allows for a zero clearance installation which WORKBENCH O OCTOBER 2005 ProFire Indoor Gas Grill Model PFINDOOR designed to fit a zero clearance opening see Buyer s Guide on page 57 Custom Countertop made with plastic laminate over a double layer of MDF see page 58 Case is designed with a large opening to Trim Strip accommodate ee adds a linear y grill A Ventilation horizontal Notes design element Drawers assembled with strong half blind dovetail joints see page 55 Brushed Nickel Pulls add a contemporary look and a nice contrast with the oak cabinet Full Extension Slides allow easy access to back of drawer Construction Details Solid Wood Frame amp Plywood Panel Doors constructed with mortise amp tenon joints see page 54 Overall Dimensions 431 W x 481 D x 36 H means we didn t need to be con cerned wi
26. wired with electricity and plumbed with gas The power line will feed two outlets one inside the compartment for the grill igniter to plug into and another that s accessible from the outside of the island for plugging in appliances see Illustrations at left The gas line needs to include a shut off valve inside the com partment You ll want to have easy access to this shut off valve so it s important to keep the gas line toward the front of the island Both lines should be fed from underneath the floor and into the compartment through access holes drilled in the bottom of the case This will leave the lines par tially exposed where they span between the floor and the bottom of the island so you ll need to protect them A simple box with one removable side in case you need to access the utilities will serve nicely The box consists of four boards ripped to width from 2x6 stock to fit under the island and then butted and together Use metal L 8 x 154 Fh Woodscrew screwed brackets to secure three Electrical outlet for kitchen e appliances Flexible Gas Line Grill Power Electrical outlet z for grill a BS ED GS ee SUTTTTT me D ce j o aoe lt I Height Cut to Fit sides of the box to the floor Once the utilities are taken care of and you ve moved the island into posi tion drive screws through the case bottom an
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