PLAN AND LAYOUT

After the working drawings are completed and approved, a plan and layout of procedures are done. This saves time and eliminates mistakes. A good cabinetmaker will always lay out and plan the work before starting to build. A number of construction problems are solved during this planning period. With a good layout and plan, those who do the work have few questions.

Layout Rod

One of the most common ways to lay outwork is to use a rod. A rod is normally a 1-inch x 2-inch strip of lumber which indicates the actual location of all the parts of the cabinet. One side of the rod is used for marking the width. Another is used for marking the height, the third side is for the depth, and the fourth side is used if other cabinets are to be built that differ in only one dimension. This technique is similar to laying out studs on a floor in rough framing. The rod shows the locations where the cuts would be - the drawers, the shelves, the rails and stiles - any detail it takes to construct a cabinet. Cabinetmakers use different techniques and methods in developing these rods and making a layout rod more easier to read.

Making a Cutting List

Once the rod layout is complete, all measurements for cutting the stock should be taken from it. A cutting list can then be made listing all the parts and sizes. A cutting list must include the quantity of each component, the thickness, width, and length of stock, exact cut of each component, and should include the type of joint for each component.

Developing a Plan of Procedure

A plan of procedure must be developed before making a piece of cabinetwork. This involves writing down all the steps of construction.

The complexity of the work may determine the order of the steps to be taken to complete a job. In most cases, the following order should be used:

1. Make a layout rod from the sketch or drawing. However, many Builders or cabinetmakers bypass this step due to their experience in cabinetry.

2. Make a cutting list, using the measurements obtained from the layout rod and drawings.

3. Select the right type of stock for the project; then cut the stock to rough lengths. Rough length is 2 or 3 inches longer than actually required. Cutting to rough lengths makes handling the stock easier and facilitates machining.

4. Face one side of the stock. Facing produces a straight surface and eliminates any cup, bow, or twist.

5. Plane the stock to thickness. This is the first step to bring the stock to size. Make sure all parts are planed at the final setting of the planer to ensure equal thicknesses.

6. Joint one straight edge on each piece. This straight edge will be held against the fence of the table saw for ripping to width.

7. Rip the stock to the required width. Use the correct saw blade for the smoothness of the edge desired. Rip all pieces of the same width without changing the setting of the rip fence.

8. Cut the stock to the overall length. This is the last step in cutting the pieces to their overall finished size. Use a stop block to cut equal lengths.

9. Make rabbets, dadoes, mortises, tenons, and bore holes; and perform other machining as necessary. Set up machinery and make all similar cuts without changing the setup.

10. Sand the inside faces before assembling. Once you assemble the inside of a cabinet, it is difficult to sand. These surfaces must be smoothed before assembling.

11. Assemble the parts. When possible, assemble the parts using only clamps (no glue or fasteners) to check the quality of fit. Then assemble the piece permanently as required. After assembly, wipe off any excess glue that may make finishing difficult.

12. Prepare exterior surfaces for finishing by sanding if the exterior surfaces were not sanded before assembly. Handle the pieces carefully to avoid marring the finished surfaces.

13. Apply the finish. The finish may consist of filling, staining, and applying clear or pigmented coatings.

14. Install the necessary hardware. Hardware is often installed before finishing; then remove and replace after finishing. If there is no danger of marring