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Could use some help with a cabinet that isn't square!

1917 Views 27 Replies 17 Participants Last post by  R B Fishin
As a newer woodworker, I'm looking for some sage-like advice.

I'm working on a cabinet that's going to have four shelves on the bottom and a few small drawers at the top. It's nothing too fancy, but I wanted to use dados for the shelves. Well, this was my first time cutting dados with a router, and it was frustratingly difficult to get them lined up correctly on both sides of the cabinet.

Ultimately, I knew some of the dados were slightly imperfect, but when I dry assembled the cabinet, everything was able to fit. So last night, I got everything lined up, clamped, and glued up. It actually came together okay, but the problem I'm now facing is that it's far from square. This has manifested in both the feet, which have a decent wobble to them, as well as in the drawer slide installation. (The drawers are not sitting flat when placed on shims on the top shelf, which leads me to believe the boards are somewhat twisted.)

My questions are as follows:

a) Is this a problem I could fix in any way?

b) I'm half tempted to disassemble by cutting the shelves out flush at the joint, sanding clean, then using something like pocket screws where I can ensure a square alignment. (I don't have the same aversion to pocket screws that most do. Haha.) I assume I would lose about 1/8 to a 1/16 of an inch from the cuts, but that would be fine. The dados would also be filled in due to the remaining shelves.

Is this something that could be done, and if so, what's the best way to get a flush cut at the joint?

Thanks in advance for any input. I feel like I've learned a lot from this project and I'm hoping to be able to clean it up a bit.


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You did fine. The trick with cabinets is consistently cut parts and square cuts.

Few things to consider for the future:
  • Before cutting parts double check your tools for alignment and accuracy. Table saw blade exactly 90°.
  • Don’t assume the ply is square from the factory!
  • Use an accurate large square. Also helps find bows. You can make one yourself use 3,4,5 triangle principle.
  • If the ply is bowed and you use a small square you will get a false reading. You can chase your tail.
  • Cutting panels square critical and challenging if you don’t have the set up. Don’t assume you rip everything and be square! If you do much of this a crosscut panel sled is good to have. Note: this is not a regular ts sled.
  • Miter gauges can work but not always depending on panel width and length.
  • If you dado one piece of ply, then rip into two sides they‘ll be perfectly aligned.
  • Dont rely on glue alone. Cabinets need mechanical fasteners (screws) glue not necessary. Staples ok on back - no nails they don’t hold.
  • Screw the shelves from the outside, do a counter bore and plug. If the ply is bowed this corrects.
  • Edge banding always gives a more finished look. Iron on is easy to do
  • The back needs to square for your cabinet to be square!

Corner clamps can be handy for holding parts while screwing but aren’t necessary. The back squares the cabinet. Be careful with corner clamps. The plastic Rockler set I have are horribly out of square. I recently bought a couple sets cheap that are “pretty good”. Not important enough to warrant Woodpecker prices. 😉

If fastening to wall a thicker back or nailer strips. Cabinet looks better it back is in a groove or rabbet.
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This had crossed my mind.

Basically the drawers are going to contain dividers and trading cards. I want them on top because I'm going to be accessing them a lot more frequently, and I'll be looking through them and pulling things out frequently.

The bottom shelves are each going to have two specific boxes that weigh between 7-10 lbs each, so between 14-20 lbs per shelf. That means that, when full (which they will be) the bottom shelves will be holding 56 to 80 lbs. My assumption was that this, along with the weight of the carcass, would be enough weight to make sure the cabinet stays put when pulling the drawers out.

Additionally, I was going to make two of this same unit and connect them at the sides with these socket cap bolts: Amazon.com. This way, if I needed more storage in the future, I could even add a third, etc. But also, pulling one drawer out would also have the weight of both full cabinets.

Does this seem sound? Is there a better way to set this up without the drawers being on the bottom?

This is an image of a previous cabinet I built for similar storage needs. The boxes on the bottom few shelves are the same that are going to be stored here at two per shelf.

View attachment 449594

Additionally, I seriously appreciate all the input I've received here! Thanks a ton to everyone who has replied.
I used to use the same style bolts I got from my vendor when I was doing some Euro cabs. Good choice. Being that there are going to be two cabs when done, levelling them in place and securing them to the wall will assure you secure cabinets that stay in square one there is load on them.
You did fine. The trick with cabinets is consistently cut parts and square cuts.

Few things to consider for the future:
  • Before cutting parts double check your tools for alignment and accuracy. Table saw blade exactly 90°.
  • Don’t assume the ply is square from the factory!
  • Use an accurate large square. Also helps find bows. You can make one yourself use 3,4,5 triangle principle.
  • If the ply is bowed and you use a small square you will get a false reading. You can chase your tail.
  • Cutting panels square critical and challenging if you don’t have the set up. Don’t assume you rip everything and be square! If you do much of this a crosscut panel sled is good to have. Note: this is not a regular ts sled.
  • Miter gauges can work but not always depending on panel width and length.
  • If you dado one piece of ply, then rip into two sides they‘ll be perfectly aligned.
  • Dont rely on glue alone. Cabinets need mechanical fasteners (screws) glue not necessary. Staples ok on back - no nails they don’t hold.
  • Screw the shelves from the outside, do a counter bore and plug. If the ply is bowed this corrects.
  • Edge banding always gives a more finished look. Iron on is easy to do
  • The back needs to square for your cabinet to be square!

Corner clamps can be handy for holding parts while screwing but aren’t necessary. The back squares the cabinet. Be careful with corner clamps. The plastic Rockler set I have are horribly out of square. I recently bought a couple sets cheap that are “pretty good”. Not important enough to warrant Woodpecker prices. 😉

If fastening to wall a thicker back or nailer strips. Cabinet looks better it back is in a groove or rabbet.
One of the reasons plywood squares aren't such a terrible idea and you can make em just about any size you want. Generally speaking they're not great for squaring up full cabinets. I use them mostly for holding two or more cross pieces together for assembly because sadly I was born with only two hands. I wanted three, but mom didn't cooperate as I was born.. Maybe next life! ;)
I believe this cabinet design will make the cabinet, top heavy. A top heavy cabinet really needs to be fastened to the wall, at the top.
Not necessarily. For free standing against the wall, once the shelves are squared up, trim the back of the "feet" about 1/8".... a bevel cut from front to back .... and the cabinet will naturally lean backwards.... the bottom of the cabinet a bit away from the wall .... as this, below, top heavy (camp) coat rack If you detect a problem, later, you can always attach it to the wall.

Sonny
I often trim my free standing cabinets this way. A tab more work, not much, but insurance of a sorts against tipping forwards.
https://flic.kr/p/zc5ZDp https://flic.kr/p/zc5Mze https://flic.kr/p/y9dE2M
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As a newer woodworker, I'm looking for some sage-like advice.

I'm working on a cabinet that's going to have four shelves on the bottom and a few small drawers at the top. It's nothing too fancy, but I wanted to use dados for the shelves. Well, this was my first time cutting dados with a router, and it was frustratingly difficult to get them lined up correctly on both sides of the cabinet.

Ultimately, I knew some of the dados were slightly imperfect, but when I dry assembled the cabinet, everything was able to fit. So last night, I got everything lined up, clamped, and glued up. It actually came together okay, but the problem I'm now facing is that it's far from square. This has manifested in both the feet, which have a decent wobble to them, as well as in the drawer slide installation. (The drawers are not sitting flat when placed on shims on the top shelf, which leads me to believe the boards are somewhat twisted.)

My questions are as follows:

a) Is this a problem I could fix in any way?

b) I'm half tempted to disassemble by cutting the shelves out flush at the joint, sanding clean, then using something like pocket screws where I can ensure a square alignment. (I don't have the same aversion to pocket screws that most do. Haha.) I assume I would lose about 1/8 to a 1/16 of an inch from the cuts, but that would be fine. The dados would also be filled in due to the remaining shelves.

Is this something that could be done, and if so, what's the best way to get a flush cut at the joint?

Thanks in advance for any input. I feel like I've learned a lot from this project and I'm hoping to be able to clean it up a bit.


View attachment 449565 View attachment 449568 View attachment 449569 View attachment 449570 View attachment 449571 View attachment 449566 View attachment 449567 View attachment 449564 View attachment 449572
I'm firm
As a newer woodworker, I'm looking for some sage-like advice.

I'm working on a cabinet that's going to have four shelves on the bottom and a few small drawers at the top. It's nothing too fancy, but I wanted to use dados for the shelves. Well, this was my first time cutting dados with a router, and it was frustratingly difficult to get them lined up correctly on both sides of the cabinet.

Ultimately, I knew some of the dados were slightly imperfect, but when I dry assembled the cabinet, everything was able to fit. So last night, I got everything lined up, clamped, and glued up. It actually came together okay, but the problem I'm now facing is that it's far from square. This has manifested in both the feet, which have a decent wobble to them, as well as in the drawer slide installation. (The drawers are not sitting flat when placed on shims on the top shelf, which leads me to believe the boards are somewhat twisted.)

My questions are as follows:

a) Is this a problem I could fix in any way?

b) I'm half tempted to disassemble by cutting the shelves out flush at the joint, sanding clean, then using something like pocket screws where I can ensure a square alignment. (I don't have the same aversion to pocket screws that most do. Haha.) I assume I would lose about 1/8 to a 1/16 of an inch from the cuts, but that would be fine. The dados would also be filled in due to the remaining shelves.

Is this something that could be done, and if so, what's the best way to get a flush cut at the joint?

Thanks in advance for any input. I feel like I've learned a lot from this project and I'm hoping to be able to clean it up a bit.


View attachment 449565 View attachment 449568 View attachment 449569 View attachment 449570 View attachment 449571 View attachment 449566 View attachment 449567 View attachment 449564 View attachment 449572
I agree with the suggestions regarding the need for a back. Now, if you have a problem with the glue holding to tightly use a heat gun to soften it. 140 to 180°F. Will soften the glue, just be careful not to scrorch the wood. I use a cord stretched across the longer corners and held inplace by clamps. It works really well if you use what's called a truckers knot. It will double the pulling force and are easy to tie off..
As a newer woodworker, I'm looking for some sage-like advice.

I'm working on a cabinet that's going to have four shelves on the bottom and a few small drawers at the top. It's nothing too fancy, but I wanted to use dados for the shelves. Well, this was my first time cutting dados with a router, and it was frustratingly difficult to get them lined up correctly on both sides of the cabinet.

Ultimately, I knew some of the dados were slightly imperfect, but when I dry assembled the cabinet, everything was able to fit. So last night, I got everything lined up, clamped, and glued up. It actually came together okay, but the problem I'm now facing is that it's far from square. This has manifested in both the feet, which have a decent wobble to them, as well as in the drawer slide installation. (The drawers are not sitting flat when placed on shims on the top shelf, which leads me to believe the boards are somewhat twisted.)

My questions are as follows:

a) Is this a problem I could fix in any way?

b) I'm half tempted to disassemble by cutting the shelves out flush at the joint, sanding clean, then using something like pocket screws where I can ensure a square alignment. (I don't have the same aversion to pocket screws that most do. Haha.) I assume I would lose about 1/8 to a 1/16 of an inch from the cuts, but that would be fine. The dados would also be filled in due to the remaining shelves.

Is this something that could be done, and if so, what's the best way to get a flush cut at the joint?

Thanks in advance for any input. I feel like I've learned a lot from this project and I'm hoping to be able to clean it up a bit.


View attachment 449565 View attachment 449568 View attachment 449569 View attachment 449570 View attachment 449571 View attachment 449566 View attachment 449567 View attachment 449564 View attachment 449572
Didn’t see this suggestion. To address the dados matching up cut them in both sides together. Clamp the two cabinet sides together interior faces up. Clamp a straightedge across the sides allowing for the distance between the router bit and the edge of the router base. Make sure the straightedge is square to both edges. Rout the dado. Then move the straightedge to the next shelf position. This should make your shelves level across the cabinet and front to back. I normally do this while the two cabinet sides are still one piece and then rip them apart to correct width. Saves from needing to clamp them together
Investing in some clamping squares will assure you never have the problem again.

Thanks! I've had a pair of clamping squares for years, and frequently wished I had a few more.
I saw this one in your link, thought it was a good deal, and pulled the trigger.

I haven't checked them all. But so far, they're all within a few thou. For twenty five bucks and free shipping, I think I did OK. And, i was able to get free shipping on (a cheap) something else that I'd had my eye on.
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