It has been challenging to get any real shop time since late August. First the workshop door (an “up and over” garage type) failed and I was locked out for two weeks while I waited for an engineer to instal new parts and service the mechanism. As soon as that was done, work pressures at the day job meant that I was chained firmly to my desk for a couple of weeks. But ggainst all odds, the joinery for the boarded bookcase is now cut and I did a dry assembly of the casework today.
The final elements of joinery were the rabbets for kick and top rail. These require a slightly different approach to the dados for the shelves, partly because of grain direction (rabbets run along the grain, dados run across it) and because the rabbets do not run the length of the workpiece. The rabbet for the kick runs into the bottom dado, but the rabbet for the kick is stopped, which brings with it a few challenges for the handtool worker.
I cut the rabbet for the kick first, as this is easier than the stopped groove for the rail. Because the rabbet for the kick runs into the shelf dado I was able to prepare a first class cut and gently saw the walls, being careful not to overcut the workpiece, or to kink my saw on the opposite wall of the dados. I warmed up by sawing the inside wall of the rabbet, which won’t be seen once the kick is installed, and then cut the show edge second. With the walls cut I then weakened the waste by chiselling across the grain, and then popped it out with a half inch chisel working bevel up. Once I was close to the final depth I moved to the router plane to clean the bottom of the rabbet.
There are several ways to cut a stopped rabbet. Where the end of the rabbet will be hidden then sawing the walls can be very quick. However I did not want to leave signs of overcutting on the bookcase as the end of the rabbet will be visible. So the approach I took was similar to chopping a mortise. After scoring deep layout lines with a marking gauge to define a clean edge for the rabbet, I chopped across the grain with my 1/2″ chisel, followed by gently paring the edges with a 2″ wide chisel. Paring the edges is delicate work, as hitting the chisel hard can cause the grain to split. But after a few rounds of chopping across the grain, paring the side walls and popping out the waste in between, the rabbet was ready for the router plane to bring to final depth.
With all of the joinery cut I tested the fit of each shelf individually, and used a large shoulder plane to adjust the fit of the shelves where needed. Then it was time to do a dry assembly of the maim casework. After processing stock since April, this was the first time that I had seen the components come together and indicate how the finished piece will look like. The dry run also helps to identify any potential difficulties for glue-up.
Next weekend I will clean up the interior surfaces of the bookcase and then glue up the main assembly.