The heat and humidity have been very high here. I made some progress and some mistakes but I probably wont get much else done until the weekend. Hopefully it will be cooler by then.
As I said in the first installment, after I glued up the case, I realized I had not cut the dados for the vertical separators. Luckily, there was (just) enough room to work.
drawer case part 2-1.jpg
Just like horizontal dados, I marked the lines out with a knife and worked along the lines with a chisel. I had to use a cheap butt chisel for clearance. I switched to the router plane to get it flat and to depth.
drawer case part 2-3.jpg
It's easy to be precise this way but it takes a little time. I got faster and more accurate by the end after only 10 stopped dados.
drawer case part 2-2.jpg drawer case part 2-4.jpg
I cut the grooves in the horizontal pieces on the table saw. Even if I wanted to, I have no hand tool that will let me make a 1/8" x 1/8" dado. I marked out the relief cuts with knife lines and sawed them by hand. I used a story stick to be sure I got everything perfectly lined up. Everything looked perfect until I got them installed. The relief cuts are off by about 1/32" on each side. A very even, precise 1/32"...
I'm confident I cut on the wrong side of the line
drawer case part 2-7.jpg
I suppose I could leave it but I'm not going to. I couldn't tolerate looking at that gap every day. The shelves will get cut into drawer sides and I'll remake shelves. It was an avoidable mistake. I'll try harder to avoid it this time.
Speaking of fixes, below is the repaired tail. I didn't spend time to match the grain. It won't be seen, so there's no point. Regardless, once it's planed smooth, it will look just fine and be strong.
drawer case part 2-5.jpg