Hey guys, My 4th of July Holiday was used to get started on the "built-in"
my lovely wife wants for our 3rd bedroom/craft room.
It won't be anything fancy. Her design criteria were: Fill the hole, give me two drawers and at least 5 shelves and paint it white to match the rest of the trim and the other shelves in the room.
The morning started out with making a "story pole" and getting the dimensions of the hole, followed by sketching up a quick drawing of what I thought she wanted. What a surprise, she okay'd the first draft. Life is good.
Two sheets of 31/32" maple ply were used for the case work. Today I managed to cut all the stock to size and run the rabbets on the pieces for the sides, top and bottom pieces.
My process was:
Step 1: I cut the two 4' x 8' sheets of ply into 16" strips by laying four 2x4's on the shop floor, placing a sheet of ply on top of the studs and using my circular saw to rough out the strips.
Step 2: The four pieces with the factory edges were then run through the table saw to a width of 15.5", then flipped and re-cut to a width of 15". Two of these pieces will be used for the 92" tall sides.
Step 3: My chop saw was used to rough out the top, bottom, fixed shelf and one adjustable shelf from the other two 15" wide pieces.
Step 4: Still on the chop saw, I cut the two remaining strips (without factory edges) in half and then jointed on edge on all 4 pieces.(I cheated and used my Delta 6" jointer. It was too damned hot to do it by hand.)
Step 5: Using my Table Saw/Sled, I squared up one end of each piece and then cross cut the shelves, top and bottom to 45", then removed the sled and ripped the pieces to a 14.25" width.
Step 6: Back to the chop saw where I cross cut the 15" wide sides to 92".
Step 7: With all the pieces cut to size, it was time to cut the rabbets in the sides, top and bottom pieces. The TS with a stacked dado and sacrificial fence made quick work on it. Each of those pieces has a 3/4" x 1/2" rabbet along its back edge.
Sorry about not providing pics, but hey, you have all seen sawdust and pieces of wood before.