Build Process
Initial Concept Design:
Created 3D model in AutoCAD to get a feel for proportions and general design features. Overall I was happy with the general design but came to the conclusion that the following adjustments would improve the design and functionality:
---1. Replace the 1"x1" square tube in the steel base frames with 1"x1" angle iron to decrease the visible thickness of the steel boarder/frame from 1" (face of tube) down to 1/8" (thickness of angle leg). This modification provided cleaner transitions, a more appealing balance between wood and steel, and an overall crisper and lighter feel.
---2. Increase the bottom drawer height to accommodate letter sized file folders on one side and add a concealed drawer on the other side.
Detailed Design:
Used AutoCAD to create 2D drawings that are detailed enough to build from. During this phase I was able to coordinate the layout of panel attachment screws, tabs, drawer slides, top plate mounting holes/slots, and secret drawer clearance needs.
Plywood Rough Cut Diagram:
Care was taken to ensure that only one 4'x8' sheet of plywood was needed to complete the project.
Steel Base after welding on panel attachment tabs
Primed steel bases during infill side panels and drawer fit-up.
Spacers were needed on the inside faces of the infill panels to provide a drawer slide mounting surface flush with the steel frame rough opening.
Secret drawer initial fit-up.
The secret drawer false front was cut from the fully assembled parent drawer box so the continuous grain pattern was maintained. Cuts were made with a thin-kerf 7 1/4" circ blade on the table saw to minimize gap between secret drawer front and adjacent drawer box. The resulting gap is approx. 3/64".
