After passing all 12 rails at the same height I proceed to cutting the other side of the tenon. Since this bit only has a 5/32” kerf it takes a few passes. But the results are worth it and the sled produces repeatable results.
Here’s the bottom rail with a completed tenon:
A test fit is looking good:
So the rest of the rails get cut in the same fashion.
Here’s a middle rail all cut up:
And the fit:
And the top rail (note the extra grove for the top panel):
And the fit:
The last cut needed is a rabbet for the ½” MDF bottom. After a few passes with the same slot cutter and same fence setting I have a ¼” x ½” rabbet in the bottom rails:
A quick mock up shows the ½” MDF should fit nicely:
Next I cut the ply panels on my not so accurate table saw. The good news is I don’t need too much precision. I cut the panels ¼” smaller on both sides for 1/16” wiggle room on all 4 sides. A quick dry fit of a panel shows everything goes together square:
So I break out the Titebond III and clamps and get to it:
After the 1st clamps come off the joints are looking good:
So I keep going gluing up the bottom panels 1st all the way around. The top rails are installed dry to help line everything up:
I’m amazed at how square everything falls into place. Here’s a pic of the final side panel getting glued in:
Here’s a shot of an inside bottom corner:
After all the side panels are in place the top rails and panel go on last. But here’s a slight flaw of this design. Because of how the top panel sits in the groves of the rails a small notch will have to be cut away in each corner before final assembly:
For this I use a fine tooth jig saw:
After a few swipes of a sandpaper the “design flaw” is fixed:
Before the top gets placed on the stand a ½” MDF doubler gets glued to the underside of the top ply panel for support.
The top rails / panel get tapped in and clamped:
After the clamps come off the tops joints (the only visible joints) are looking good. Even though there is some dried glue on them. Nothing a little sandpaper can’t take care of a bit later:
