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16-Drawer Apothecary Chest

With Step by Step Instructions -- Completed 5/23/05 --

Apothecary chests have been around for centuries and are a great place to store almost anything.  Originally designed for storing herbs, and medical powders, they have evolved into a "Catch-All" for almost anything, from sewing equipment to nuts and bolts.  Below is a step by step process of how I made this chest, and you're welcome to follow along as I build this wonderful 16-drawer apothecary chest! 
 
16 Drawer Apothecary Chest

The Original

Miniature (Scale) 16 Drawer Apothecary ChestDownload the plans

Simply click this link, and provided you have Adobe PDF reader you will bring up a page in a new window you can save and print out.  The instructions provided in the PDF file are very basic - more elaborate instructions will be here if you need them. 

My Copy before I put the final touches on it
Tools needed to make this 16-drawer apothecary chest.

12 inch ruler
- steel preferred - I use as a straight edge for cutting!
My custom graph paper - To measure with, and for checking final cuts - Download here.
Vernier slide caliper - The ones that have the depth measuring blade that extends when opened.
#5 and/or #2 Precision Knife - I used both, but either will work.
Razor saw and miter box - I always use the finest toothed saw I can find!
Strip Cutter - Makes a lot of the cuts much simpler.
220 to 1500 grit sand paper - Single sheets are available at the hardware store.
Stain & Varnish - Your choice
Set of Needle Files - The round, curved and flat files are needed.
Gluing Jig
- Keeping the parts square during gluing is very important to construction.
The Wood & Other Items needed for the chest!

3" x 1/16" x 24" sheet of Basswood - Some of this wood will have to be sanded thinner to achieve the thickness required for the drawer sides and ends!
3" x 1/32" x 24" sheet of Basswood - This wood will have to be sanded thinner to achieve the thickness required by the plans for the chest back and drawer bottoms!
12 white porcelain knobs -
I haven't decided yet how to make these, but am sure to let you know as soon as I figure it out!
pieces for the 16 drawer apothecary chest - in 1/12th scale (miniature)
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Cutting the pieces for your chest.

There are a total of 133 wood pieces that need to be made for this chest, but don't despair as 120 of these are duplicates of other pieces.  In reality there are only 13 different sized pieces to make. 
When cutting the wood for your chest, make sure that the grain runs the same direction as the longest side of wood you cut!  This is important to insure you created the strongest structure as possible.
We are going to duplicate many of these pieces by means of making a simple jig, and that process will be explained later. 

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Use the Strip Cutter!

The strip cutter is a wonderful and indispensable tool to have.  It is designed to cut varying sized wood strips, and can be used to make duplicate cuts very simple. 
Because you're cutting wood that is harder than balsa, it is best to use a more sturdy blade than the #11 blade provided with the strip cutter, I prefer the #2 blade.  Make sure that your cutting surface is clean from any debris that could cause the cut to become un-square. 
Start with a fresh edge on the wood to be cut, or an edge that you last used the strip cutter with.  Expand the blade out to the width you want the piece cut, and adjust the blade so that it only cuts into the wood enough to score it.  Always run the length of the wood you're cutting, trying to stop half way will only result in your wasting the wood later.  The extra wood cut, can always be used for the project later. 
After the initial cut, adjust the blade so that it cuts deeper, and repeat until the wood is split.  Please remember it is better to take more time in cutting the wood, as you will get a more accurately cut piece that way, than if you try to make a deep cut and cut quicker.

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(1) Top 0.0625 x 1.25 x 2.5833

Making sure the grain runs the long way (2.5833") cut the top piece using the strip cutter to cut the full length of the basswood strip, the remaining wood after the top is cut to length can be used to make the sides, filler strip and partitions below!

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(2) Sides 0.0625 x 1.1875 x 2.5208

There are two sides to this piece, you can cut these pieces using your strip cutter, and then cutting to length with the miter saw.  Each side piece will have to have a rabbit cut into it later, but I first want to cut the back piece before I cut the rabbit, to make sure that the rabbit is the right size for the back.

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(1) Filler Strip 0.0625 x 0.0625 x 2.3333

The filler strip is used to fill the space between the top partition and the top of the chest. Using the strip cutter, adjust the blade to trim off 0.0625" off the remaining wood strip, be careful with this piece, as it is very fragile, cut to length. 

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(12) Drawer Guides 0.0625 x 0.0625 x 1.0417

Using what remains of the piece from the filler strip above, you can cut several drawer guides - if you need to, you can cut another 0.0625 strip off the remaining wood, before you cut the partitions below.  Cut each piece 1.0417" in length using the jig below for speed.

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Using a jig to cut multiple pieces the same length

I have found the fastest way to do this is with a simple jig for the miter box.  Just cut a piece of wood to fit edge to edge inside the miter saw, and hold in place with a clamp, then slide the piece to cut up to the block and cut with the saw.

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(5) Partitions 0.0625 x 1.1667 x 2.3333

These are the "shelves" that divide the drawers from the drawers below or above.  There are 5 of them each one can be cut to width with the strip cutter and then to length, by using the miter saw.

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(12) Drawer Dividers 0.0625 x 0.125 x 0.5052

Using the strip cutters and the 1/16" basswood strip, cut a strip 0.125" in width the full length of the basswood strip, then using the miter saw and jig, cut to length. 
When I start construction, I may decide to make three long drawer dividers, and use dados to fit to partitions, instead of using 12 individual dividers.

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Base Front 0.0625 x 0.3542 x 2.5833

With the strip cutters, cut a 0.3542" wide strip of wood the full length of the 1/16" basswood sheet.  Then cut to length in the miter saw.  A pattern will be transferred onto this wood to be cut out for the front design on the wood.

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(2) Base Sides 0.0625 x 0.3542 x 1.25

From the same strip of wood cut for the base front, using the miter saw, cut two side pieces 1.25" long each.  These too will have a pattern transferred and cut out as shown below.

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Transferring the pattern to the front and side pieces

Using the PDF file and the custom graph paper, draw the design and then transfer it to each piece of wood.  I plan on providing a printout later, to save you the trouble of doing it yourself. 

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Cutting the pattern out of the front and side pieces

Cutting out the pattern is relatively easy using only your knife and a set of needle files.  You first begin by cutting to the pattern from the edge of the wood, using straight cuts, make sure you don't cut beyond the pattern itself.  These little nibbles are then easy to remove, you then use your needle files to file the wood to the pattern.

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(16) Drawer Bottoms 0.0104 x 0.4479 x 1.1458

Using 1/32" wood sheet and the strip cutter cut a single strip 0.4479 inches in width the full length of the wood sheet.  Before you cut these to size, sand the thickness to the required 0.0104 to 0.0216.  Now cut 16 of bottoms using the miter box jig to a lengths of 1.1458 inches each, later we will sand the edges.

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(1) Back 0.0208 x 2.3958 x 2.3958

Again using the 1/32" wood sheet cut the back piece out.  We will be thinning this wood to the correct thickness later!

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(32) Drawer Sides 0.0417 x 0.4896 x 1.1458

Using the 1/16" wood sheet, and the strip cutters, cut 3 or 4 strips 0.4896 wide the full length of the wood sheet.  Allow to sit until we add the dado cuts later. 

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(32) Drawer Ends 0.0417 x 0.4583 x 0.4166

Using the 1/16" wood sheet, and the strip cutter cut 1 strip 0.4166 inches in width.  Again using the strip cutter set to 0.4583 inches, cut 32 drawer ends.  I found it was easier to make two cuts -- one from each side of the wood strip.  This also make the finished cut more accurate.

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(16) Drawer Fronts 0.0625 x 0.5 x 0.5

The final wood pieces are the drawer fronts.  Using the strip cutter and the 1/16" wood sheet, cut a single strip 0.5 inches in width the full length of the sheet.  Using the same adjustment on the strip cutter cut the 16 drawer fronts.  Making multiple cuts from both sides works best for me, and again provide the most accurate cuts.
 

Sanding, Sizing


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Sanding the Back - then rabbit the Sides

Currently the back is 0.03125 (1/32)" thick, and it needs to be reduced to 0.0208" thick.  I'm using the handy sanding tools I mentioned in my journal page for December 15, 2005, to sand to the thickness I need.  Be very careful when sanding the back, as it is going to become very thin, and will fracture easily. 

 

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Once you have achieved the thickness for the back needed, it is time to cut the rabbits into the side pieces, the back will fit into.  Using your back as a thickness guide, adjust the strip cutter to the thickness of the back piece.  Adjust the blade depth so that it cuts to the depth of 0.0313 inches.  Slice the back edge of each side - now using your x-acto knife carefully cut along the edge, cut to the depth of the initial cut, and remove using the edge of the x-acto knife.

Set the pieces aside for later.

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The resulting dado will accommodate the back very nicely.  Now do the same for the other side piece, and set both pieces aside for later!



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Cutting the dado, Sanding the Drawer Sides and Bottoms

The easiest way to cut the dados for the drawer side is to use the strip cutter and "etch" the section to be removed.  You must be very careful of the depth of your cut when making these dados, as we will sand to the correct thickness later. 

Cutting the dados is very precise work and will require a bit of practice and patience. Careful adjustments on the strip cutter, will make this process go much faster and easier.

For the drawer sides, you'll want to cut the dado to a depth of 0.0208 inches. Carefully make sure the knife blade cuts only to this depth - test on a scrap piece of wood and measure carefully. Tighten the screws holding the knife blade - tight so that the blade doesn't move.

Adjust the blade out from the strip cutter's edge to .0313 or 0.0407 inches (depending on how thick the bottoms are) and make the cut on one edge of all the drawer sides. This cut is the top edge of the grove (dado) where the drawer bottom will go.  Make this cut on each strip before preceding.

Now reduce the cutter to 0.0209 inches from the strip cutter edge and repeat the cuts on the same edge of each drawer strip.

Now adjust the blade out from the strip cutter's edge just slightly and repeat each cut making small width adjustment until you reach the top most cut made in the first step.

I have found that removing the wood between the cuts is very simply now, just use the tip of the knife blade, or a chisel modified jewelers screw driver, and chisel or "flick" each section out. Make sure you use pressure towards the thick side only, as the bottom edge might fracture off if too much pressure is used. I use the edge of the knife to smooth the bottom once the sections are removed - I just move the knife blade in a scraping motion, side to side, to smooth - not in a sawing motion that cuts.

You can now cut the dadoed side strips into the 32 sides of 1.1458 inches long each.

 


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Currently the drawer sides are 0.0625" thick and need to be thinned to 0.0417 inches thick.  With 32 sides to sand down, it is best to make a simple sanding jig. 

To create this jig, just select a 3 inch long piece of wood wide enough to accept a dado the size of the side piece to be sanded.  Using the miter saw cut to the depth of the thickness of the piece of wood to be sanded "0.0417 inches" - then cut the excess out using the strip cutter or a chisel. 

 

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Next glue a retaining piece to one edge of this jig to hold the side piece in place while sanding. 

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At both ends of the jig glue another piece running perpendicular to the dado.  It is very important that these side pieces are glued in the correct position.  To do this, cut a strip of the sand paper you're going to use to sand the side pieces, to 2 1/2 inches wide, sit the dado section on the sand paper and then glue the side pieces in place making sure the entire jig is square, also make sure the side rails touch the table NOT the sand paper! -- this way they will act as a stop when you're sanding the side pieces. 

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Using this jig will speed up the sanding process greatly, and increase the accuracy of each side piece.  Using a 2 1/2 inch wide strip of sand paper, sand each pieces of wood - make sure the side rails on the jig remain on the table and not on the sand paper.

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If the jig was built properly, you should feel less resistance as each side piece reaches 0.0417 inches thick.  I realize that this is very tedious work, but in the end, the results will make it worth the effort, as the resulting piece will look more like the real chest, even when taking close up pictures.  Your drawer sides should be now ready for assembly!

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You'll need to make a new sanding jig for sanding the drawer bottoms.  Using the same process as above, create the jig and use it to sand the 16 drawer bottoms to a thickness of 0.0104 inches.  This is pretty thin, so if you want, you can leave them 0.0208 inches thick instead.  If you do that make sure you use the red measurements for the dado cuts above.  Thin each bottom piece to 0.0104 or 0.0208 inches thick.  I realize that this is very tedious work, but in the end, the results will make it worth the effort, as the resulting piece will look more like the real chest, even when taking close up pictures.

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Preparing the Drawer End Pieces

To begin with just trim up the edges on these 32 end pieces a bit.  The final sanding will be done after the drawer is assembled!

 
 

Putting the Apothecary Chest Together


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Building the Shelves

Begin by gluing the filler strip to the front edge of the top shelf (this is not the top but one of 5 shelves).  Make sure that it is flush with the front and side edges of the shelf!

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Next mark the remaining 4 shelves for the placement of the drawer guides.  These are marked by placing the first guide mark in the center of the top - flush with the back edge.  The remaining two guides go 1/2 way between the middle guide and the edge.  Illustration shows the measurements.

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After checking your measurements twice - Glue the drawer guides on only one shelf, again double checking the measurements.  Allow this drawer guides shelf to dry.  After the drawer guides have dried - use this shelf as a guide to glue up the second shelf's drawer guides, remember if you face the two like in the picture, one set of drawer guides will be flush with the top side, and the other set will be flush with the bottom side. 

Using the same original piece - glue up the other two shelves and drawer guides.  Marking the back edge of the original is the best way, as it won't show in the completed Apothecary Chest!

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This is where things are going to change a bit from the original plan.  I'm going to change the original design, of using 12 drawer dividers, to a plan using 3 long dividers.  But don't despair, as you're still going to use the original 12 to insure proper spacing between shelves. 

Make sure that each drawer divider is exactly the same length as the rest of the drawer dividers - 0.5052 inches in length.  Now lightly glue each of these dividers into its proper place as indicated in the picture to the right.  Do this for all 4 shelves.  When I say lightly, I mean very little glue, these dividers are going to be removed later!

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After you have finished positioning the drawer dividers, it is time to assemble the shelves.  Using the gluing jig, glue each shelf into place.  Again use very little glue, as these dividers will be removed later.  It is also important to make sure the shelves remain parallel to each other.

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After you have assembled the shelves it should look like this picture.

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Next comes the assembly of the main box for the Apothecary Chest.  Remember the dados on the sides have to go to the back side of the shelf assembly.  Using a pencil and marking lightly, mark the position of each shelf on the sides.  The top filler piece is to be flush with the top edge of the sides, and flush with the front as well.  Do one side at a time, and allow to dry completely before continuing!
A BIT OF A PLAN CHANGE! While the sides are drying, you'll need to make the single piece drawer dividers.  Take a piece of 1/16 inch wood (0.0625) and the strip cutter, cut a strip 0.125 inches wide by at least 3 time the length of the chest assembly.  We'll cut each to length later!

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After the sides have completely dried, it is time to remove the short drawer dividers and notch the shelves to accept the new one piece drawer dividers.  Using the edge of the knife, cut the glue joint between the shelf and the drawer divider.  After all 12 have been removed, carefully mark a 1/16th inch section to be removed, be very accurate on the positions of these notches, and cut smaller than the 1/16th inch to insure a tight fit! 

As indicated in the picture, use the knife to notch out the area for the new drawer dividers to fit into.  DO NOT cut a notch in the top or bottom shelf!   

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After cutting the notches a bit less than 1/16th inch wide and to the depth of the drawer guides, cut the long strip into 3 equal length pieces that will fit tightly (but not too tightly) between the bottom shelf and the top shelf.  Cut a hair long, and then sand to length - we want a tight fit, but not one that will bow the shelf!

Carefully check the fit, and when satisfied it will fit properly, glue into place.  You should end up with a box that looks like the one here!
  If for some reason your drawers guides are not aligned correctly, they can be removed and be glued as needed  Use the same technique as you used to remove the drawer dividers.

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The next step is to miter the base front and side pieces.  Simply cut opposing 45 degree angles on both ends of the front base piece.  Next miter a matching 45 degree angle on the front side of each base sides -- make sure the angles are correct before you cut!

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I prefer to glue up the base, before I attach to the main box, which allows me to make any alteration necessary.  I use the gluing jig to insure that the pieces are square and straight.  After the assembly is dry, I make any needed changes before I attach to the main box.

Glue one base side and allow to dry!

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Glue the second base side and allow to dry!

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Position the glued base onto the main box, flush with the bottom shelf - make sure the sides are also lined up correctly.  Clamp and allow to dry completely!

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After the glue has dried, do any minor sanding needed to remove any excess glue. 

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The next step is to put the top on the chest.  It is flush with the back edge and over hangs evenly on the sides and front.  Glue in place and allow to dry completely. 

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Making a filler to hide the imperfections you might have!

Whenever you build a relatively intricate miniature like this one, you are bound to have a few imperfections that you want to hide.  Wood filler has never satisfied me, especially when it comes to staining, so I designed my own filler, that is easy to make and use.

To begin with you need to collect the sawdust from the fine sanding that you do.  Whenever I sand something, I take the sawdust created and store it in a box, labeled for the kind of wood it comes from. 

Using a scrap piece of wood, determine the shade of stain you want the Apothecary Chest to have.

Now on a piece of thick glass, or a plate, take a small pile of sawdust, mix in a small amount of stain, until you reach the color you have decided on,  Mix very well, mashing till all the wood is stained the color you have chosen.  Set aside and allow to dry completely, stirring occasionally to keep from clumping.

 

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Stain the chest to match the sawdust mixture you have made.  Make sure you remember that the stain will lighten as it dries.  You might as well stain the back also at this time!

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Once the chest is dried, and you're sure of the color, mix a small amount of stained sawdust with a bit of varnish till it reaches the consistency of thick peanut butter and use it to fill the imperfections.  I use a plastic bag to mix on, so I can dispose of later. 



 

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NOTE!  when you mix with the varnish - the wood filler will take on a darker color, the same way stained wood does when the finish is added.

Allow the filler mix to dry completely and then sand.  Re-stain as needed!
 

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Go ahead and finish the chest as well!  Sand lightly between coats (steel wool works best) and finish to your taste!

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Building the Drawers

Each drawer is made from 6 pieces of wood - 2 sides, 2 ends, 1 bottom and the drawer fronts.  Assembling these drawers will be much easier if you create a jig to help you.  There are several ways to make this jig, the easiest is by using a commercially available gluing jig with sides, or by making a simple one out of wood pieces. 

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Start by double checking the size of the drawer sides, ends and bottom pieces.  Whenever you deal with small items, even the smallest error can make a big difference.  I test fitted the pieces and discovered that I needed to remove a small amount from the bottom edge of the end pieces, in order to accommodate the bottom piece.  I used the strip cutter to remove this section.

First put the end pieces on one side, and allow to dry!  Make sure that the dado is pointing up and that there is enough room to slip the bottom piece in place once dried.

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Next glue on the other side on, again making sure the bottom will slide into place as needed!

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Test to make sure this drawer fits into the Apothecary Chest properly, remember the drawer front has to be added later, so allow for it when checking the fit!  If everything fits correctly, continue to next step -- Otherwise make adjustments then continue!

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Next you slide the bottom piece into place, you can always sand the edges slightly if needed to prevent the piece from bowing when slid into place -- glue only one end of the bottom into place. 

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The drawer is now complete except for the front panel which will be added later.  Now repeat the process 15 more times. Once all 16 drawers have been completed, set aside for later.

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After the drawers have dried completely, sand the edges to make sure you have flush and flat edges. 

Now its time to attach the front panel to each drawer.  Make sure that the bottom and side edges of the front panel aligns properly with the bottom and sides of the drawer.  There should be a slight overhang on the sides, which we'll adjust later.  Allow to dry completely. 

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Once all the drawers fronts are glued and dried, slide each drawers into place, additional sanding on the sides of the drawer may be needed in order for the drawers to fit!  Once all drawers are in the chest, number each drawer 1 - 16 on the back of the drawer end piece with pencil. 

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This next part requires a good eye and a bit of patience!  Sand the edges of the drawer fronts to fit into the opening with close tolerance, but not so close that it is hard to slide!  Once the proper size is achieved, round the front edges of the drawer front. 

Do any needed touchup sanding and prepare to stain.  When ready, stain each drawer to match the chest and allow to dry completely.

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While you're waiting for the drawers to dry, glue the back into place.  Make any adjustments needed for it to fit in the dados!

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The only thing left at this point is to finish and add the drawer pulls. 

To finish: Remove the drawers and put the finish you prefer on the chest.  You do not need to finish inside the chest, or the back, as those needs to remain unfinished the same way a real chest would be.  You can also wait till the project is complete to finish - I do this so that I can add "imperfections" to the chest for realism. 

The drawers only need finish put on the drawer fronts, you can if you want add a bit of wax to the sides and bottom in order to allow to slide more easily!

Allow to dry completely between coats - Finish to taste.
 

The Final Step!


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Preparing the Drawer Pulls

I've thought of several ways to make the drawer pulls, from Sculpey to wood. 

Having never worked with Sculpey before, I decided to do a bit of experimenting to see what would work best.  If you have any hints - send them to me as I am a novice with Sculpey.

I've tried to make molds, rolling jigs, and even tried it free hand, I don't have the dexterity in my fingers for that to work.  So I've decided to make them out of wood.
I'm starting with a 1/8th inch dowel and using my lathe (a drill will work just as well if mounted properly) and a set of small needle files to make the pulls. 

Mount a short piece of dowel into the jaws of the lathe, or drill, only allowing about 2 inches or so to extend.  You want to make sure that the dowel doesn't bend excessively while filing it. 
Once you have the dowel mounted, you need to mark the area needed to be cut out.  While the drill or lathe is running and using the picture to the left, mark the areas that need to be cut out with a pencil. 

 
Now using your flat needle file, slightly round the end of the dowel.  Now using the round or 1/2 round needle file, remove the curved section -- make sure that back end of the curved section is less than the front "knob" part of the pull.  Lastly using the square needle file, cut the post section of the pull, then remove the knob with your X-Acto knife. 

Repeat the process for each pull -- NOTE! File the end flat before marking the new pull.  Practice make perfect, so don't be afraid to cut a few extras!

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The Plans call for Porcelain pulls, so you'll need to paint the pulls white - I don't paint the post section, I believe the glue holds better that way!  Allow these to dry completely.  Using an extremely fine sand paper smooth them out a bit before you use!

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Using a straight edge or center finder, mark the center of each drawer.  Don't be afraid to adjust with our eyes, if it doesn't look correctly centered.  You are dealing with very fine measurements and even the slightest offset can make it look bad!

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 Now using an appropriate size drill bit, drill a hole all the way through the center of the drawer front, sized to accept the post on the drawer pulls.  Be careful when drilling through the back, as the wood might splinter -- I put another piece of scrap wood behind the drawer front to insure that doesn't happen. 

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The drawer pulls are very small as you can see - you need to be careful adding the glue!

Test fit each drawer pull before you glue it.  Cut the post to length if needed, and remove any excess glue before it dries.
Apply glue to the post, and glue in place. 
Scale (Miniature) 16 Drawer Apothecary Chest
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My Scale (Miniature) 16 Drawer Apothecary Chest

THE 16 DRAWER APOTHECARY CHEST IS COMPLETE

  Like any piece of furniture, they are never perfect!  So I always like to add a bit of distress to the piece before I display in a room.  Rounded corners, instead of sharp crisp corners.  Maybe a mouse hole, or worm holes.  A cigarette burn, or even a glass ring or two, any of these can make the piece look more real. 

I would love to see your completed projects - and remember you can always ask questions in the forum if needed.
 

I would like to see "YOUR" APOTHECARY CHESTS in this section!  So  Me a Picture and I'll add it here!

 

 

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