Building A Custom Hardware Cabinet

The cabinet is crafted from 5/8-inch Baltic birch plywood, known for its exceptional strength. Given the weight, I've incorporated a 1-inch rabbet along the back edge – a quarter-inch for the back panel and three-quarters for French cleats, offering the option of wall mounting. Strategically planning, I run 5/8-inch dados before switching to a 1/8-inch dado. Using my accurate table saw fence, adjustments between cuts are swift.

Assembly is brisk; nails temporarily secure parts while the real strength lies in the glue. The drawer bottoms, fashioned from 1/8-inch white acrylic, undergo a unique process. Taping a stack to a template, I use a flush trim bit to radius the front corners. The drawer bodies, cut from 1/8-inch clear acrylic, have edges joined to remove saw marks, ensuring solid bonding.

For bending, I've designed a system that permits simultaneous heating and bending. Using a form to maintain size accuracy, the sides and front form a single, continuous piece. Ensuring squareness with a form featuring a 90-degree stop, backs are bonded to sides using weld-on acrylic cement, melting the parts together rapidly but reaching peak strength in 12 to 36 hours.

Drawer sides, initially longer, are trimmed to maintain a half-inch lip for handling and labeling. Flame polishing the plexi edges adds clarity and reduces sharpness. With a few coats of lacquer, the drawers pass the drop test, demonstrating remarkable durability.

These drawers prove ideal for organizing hardware acquired from an auction. The clear, tough design allows easy visibility and portability, making it effortless to access fasteners at the workbench. Inspired to create your own? Subscribe for more woodworking videos and let the creative process flow in your shop!
Music
Deliberate Thought by Kevin MacLeod is licensed under a Creative Commons Attribution license (https://creativecommons.org/licenses/...)
Source: http://incompetech.com/music/royalty-...
Artist: http://incompetech.com/