This is part 2 of my file rack build using ABS tubing. You can find part one of this project here.
My design for the file rack is to contain the ABS tubes with two solid end pieces attached by strips at front and back. These strips will sit in notches in the side pieces. At the bottom will be a flat panel with a set of 3 small strips running lengthwise across it. This will provide support for the bottom of the tools. It will also have a gap where saw dust and such can escape the bottom of the tubes.
Cutting the notches
I started by laying out the notches. No measurements here, just laying things out so they look good. I made my marks directly from pieces using a knife and a Veritas marking gauge.
The lines are a little hard to see but here they are cut in below.
Given that this is just a utility piece, I could go straight to the saw now. However, I like to take advantage of a chance to practice my “first class cuts”. I do this by taking a chisel to cut a trench to the waste side of the knife line that forms a trench for the saw to ride in.
This helps to keep the edges of the joint crisp and clean since they will be visible in the finished piece. As I mentioned, the Chinese elm is not working as well as I’d hoped. You can see that even with the knife and chisel work, the edges are not particularly clean.
A quick cut with a back saw forms the edge of the notch.
I put a couple more kerfs into the waste section and then use a chisel to clear the bulk of the wood. It’s important to work from both sides here and at an angle moving up and away from the base line.
The result is a slight ridge in the center of the waste. This can be subsequently removed and smoothed with a router plane.
Note that I’ve clamped a second piece next to the one I’m working on. This provides the needed support for the base of the router plane when bridging the notch. In this case, I was using the other side but any offcut with a straight edge will do the trick.
A quick check of the fit of the notches. You can see the checking that I talked about in my earlier post. Doesn’t look great but this is for the shop and shouldn’t impact the function.
Finally do a dry assembly to check things. The tolerances are tight enough that it holds together by friction until I insert the tubes, then I needed clamps for support.
Next steps are to build the bottom, assemble the file rack, and put on a finish of some sort.
Thanks for reading!