Townsend Style Chest

P. Michael Henderson

3/20/05 - Chest glue-up!  I got the chest glued up today.  Everything went together pretty well, including the dovetails on the end of the blades, which was a difficult joint to make.  I fitted the back panel to the case but I'll put it aside now while I finish many of the other things that I still have left to do.  I'll begin working on the drawers next, along with the base.

3/17/05 - I made all the web frames today.  I only show one in the picture below because I don't want to keep putting the blades in and out.  Next, I need to disassemble the case, make the 45 degree cut on the cockbeading, and sand all the pieces in preparation for gluing up the case.  I glued up the frame and panel back yesterday but won't be putting it on for some time.

3/15/05 - I completed making the dovetails for attaching the blades to the chest sides.  I made these joints by cutting the "tails" on the blades and then cutting the tail sockets in the side.  I held the blade up against the sides and marked the side for the shape of the tail.  All-in-all, I'm satisfied with the joints.  Next, I need to make the web frames, glue up the back frame and panel, and cut rabbets into the chest sides for the back.  Then I can start on the drawers.

3/14/05 - Last week was sort of a lost week.  Norma was in the hospital for three days so I didn't do much woodworking.  I'm getting back to work on the chest and am stating to install the blades (see picture).  I need to build the web frames onto the blades which I'll do as soon as I finish fitting the blades to the chest sides.  This joint is difficult because it needs to be very precise, but by taking it slow, I seem to be doing okay.

3/8/05 - I cut the grooves for the applied molding but haven't had much time to work on the chest over the past few days.  Additionally, I had to order a pattern router bit to cut the dados in the side of the case, which I won't receive until the end of the week, at best.  So I expect my next update will be early next week.

3/5/05 - Over the past few days, I practiced making the "blade to case side" joints.  While I can make them with the cockbeading cut into the side, I can't do a good job consistently.  Because of this, I'm going to take Alan Turner's suggestion and apply the beading.  Over the next couple of days, I'm going to practice making the joints with a 3/16 rabbet cut into the side of the case, where the beading is now.  I'll update you on this effort in a couple of days.

3/2/05 - I practiced cutting the "blade into the side" joint today.  I cut a slot in the side with a spiral bit first.  Then, I cut the 45 degree cut (where the beading is) with a 45 degree bit.  Finally, I cut the dovetail with a dovetail bit, carefully working the cut closer to the line on both sides.  Then I cut the blade with the same 45 degree bit and the dovetail bit, making the cuts gradually closer as I did trial fitting.  The only problem I really had was some tearout on the blade from the dovetail cut.  I need to find a way to put some backer material on the blade when I make the dovetail cut.  This is not easy because of the beading on the blade.  I'll have to try  a few more things tomorrow, and make sure I have a good process before I try to cut the actual stock.  Note that I'm not applying the beading but cutting it directly into the side stock.

3/1/05 - I finished making all the blades today.

2/28/05 - I'm now in the process of fabricating the drawer dividers (blades).  I have one installed and one fabricated but not installed yet.  The problem in building this chest is the level of precision required in fabricating and installing the parts.  For example, the profile of the blades must match the drawer fronts, and all must line up so that the blockfronts appear straight and in-line.

2/23/05 - I finished roughing out the blockfronts today at 3/4 inch.  The difficult part was rounding and smoothing the curves of the innie portion of the blockfront.  I cut the curve to rough shape with gouges and then smoothed it with a Nicholson 49 rasp. 

I liked the way the outie portion looked, the way it came out straight and then curved over, so I'm going to keep it that way.  I need to decide if I want to do the innie the same way or leave it the way it is.

Next, I'm going to cut the drawer dividers.  Fitting them into the side pieces will be a real challenge.

The story of the chest continues here.