Cabinet for Tea Bag Holders #9: The Base - The part with a Hundred Cuts (Well not that many)

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This is part 9 in a 11 part series: Cabinet for Tea Bag Holders

  1. Getting Started
...
  1. The Last Door Details
  2. The Base - The part with a Hundred Cuts (Well not that many)
  3. Inserts for doors
  1. Finishing touches

This is probably the most involved piece in the project (yes, even more than the doors). If you refer back to the first part in this blog you will see the base design is heavily influenced by the radio in the second reference image. 
 
First, the base is cut to its overall size.


I’m going to need a template for a document slot. This takes a little creative clamping.


And we have a template.


I set the router table up with a guide bearing bit and used some double stick tape to hold the template in place.


And we have a pocket roughed out.


All that is left is to square up the corners.


The rest of the base work involves several settings on the router table. Last time I tried to count I came up with over 40 different positions of bit depth and fence stops.

I added a sacrificial layer to the base and prepared a couple setup blocks.


Here are some views of the cutting sequence.








I did my best to get each of these cuts positioned to better than 0.005 inches. The details are mirrored on the other side. 

 I then repeated the entire process with my 1/16" bit (with no bearing). This time I cleaned the bit first.


And here is the result. You can see a little bit of tear out but after this much effort invested in the part I'll do my best to work with it.


Next is to add a finger relief to the document slot in the back. I used a chamfer bit and fence stops.






And I then repeated the process on the lower back of the box.






I put together a description of the history of the tea bag holders and the wood used in this cabinet. My wife then created a little booklet and envelope for it.


It's a perfect fit in the pocket!


The finger relief provides just enough access.




The final step for the base is to provide for screws to fasten it to the box.


A total of 4 screws are used.


That takes care of the construction of the box and the base. Next up is the inserts for the doors - all 14 of them. 
More of the extreme precise setups on the router, very nice work.
Thanks Oldtool, the base turned into a lot of work but it was worth it!
Woah, very cool, and love the jigs and steps to make it!

~ Mystery by Design ~

I might be stealing some of your excellent instructions to make an art-deco blue tooth speaker.....
That would look awesome! Go for it. If you need any extra info let me know.