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I am somewhat new to this so bear with me. This is the first project I have attempted to engineer myself.

I am making a cabinet for a bench top drill press. The finished cabinet will be 23-3/4" square and 31-3/16" high (to allow for 4" casters which will bring the entire assembly to just under 36" high when complete. I am making the sides, back, top and bottom from 3/4" birch baltic plywood. I intend to have six full extension drawers in the front.

The sides are 23" X 31-3/16" (this will allow for the addition of a 3/4" face frame to bring the completed depth to 23-3/4".) The back is 22-3/8" wide (when I add the width of the two side pieces this will bring the width to 23-3/4") by 31-3/16" high.

I have two questions. My first question involves the joinery I will use to made the cabinet box. I was hoping to construct the box using butt joinery, Kreg Screws and either Titebond III wood glue or Gorilla wood glue. I am also going to add vertical aluminum angle pieces (interior dimension of 1-1/2") at each corner for additional strenth and so that the cabinet matches a router cabinet I built. Will butt joinery, pocket screws and glue provide a strong enough joint? (I can certainly use rabbets, but I was hoping to simplify the process.)

Second, although the birch baltic plywood is nominally 3/4" plywood, it is actually 11/16" in width. Assuming I use a butt joint and no rabbets, what settings should I use on my Kreg pocket jig and what size/type of pocket screws should I use?

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Hi Michael,  It sounds like a nice project to me.  Your design looks good and should provide a very nice feature for your shop.

In answer to your question about strength the butt joint with pocket hole and glue will be strong enough to the project.  Although there are other options like the dado or rabbit construction, however the pocket hole technology would be faster and would provide the strength you need for what you are doing.  Just be sure to pl;ace the pocket holes about 4 to 6 inches apart with one is each corner.  If you are over lapping the top you can add a lot more strength by pocket screwing it to the sides and back.  I assume you are using a face frame as well as this too will add strength to the cabinet.  Pocket screw and glue the face frame to the cabinet as well.

You asked about settings on the jig.  set it for  3/4 inch material and use 1&1/4 inch screws.  I have excellent results using titebond glue and usually use the origional  type.  From what I have found out about gorilla glue is that it lacks sheer strength even though the bond for pull apart is great.

Something to keep in mind when using the full extension slides.  Depending on the weight of the drill press and its foot print, keep it as far to the back of the cabinet as you can and secure it to the top with bolts.  If you overload the drawers with weight and open the upper drawers to their full opening you can cause the cabinet to tip forward.  I would make the drawer depth of the uppers less that the lower drawers.   Be sure to post photos and is is nice to see photos of the project in construction as well as the finish.  Enjoy your work and work safely!!!!

Great suggestions. I am going to position the drill press as far back as possible and will secure it to the top with 6/16 x 20 bolts inserted into t-nuts installed in the top. I am using a face frame which I will secure to the top, bottom and sides with glue and pocket screws.

I figure most of the force will be down and not lateral. I will probably mount the top inside the back and sides (for aesthetic reasons), but it will be resting on a 1X3 In each corner which will be secured to the sides. That should provide some additional support against the downward force.

I will take some photographs during and after construction and will also post a photograph or two of the router table.

My usual practice on drawer storage is to put the heavy stuff in the bottom. If I can I usually make the bottom drawer double height because that encourages me to keep heavy stuff there. I think it is always best to keep the CG as low as possible.

Once again, thanks for the suggestions. It is great to be a member.

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