Step 1: Mark the Dowels
Step 2: Drill the Dowel Holes
Step 3: Mark Up the Legs
Step 4: Mark the Dowel Positions
Step 5: Smooth the Edges
Step 6: Join the End Rails and Legs
Step 7: Attach the Side Rails
Step 8: Secure the Shelf Slats
Step 9: Make the Top
Produced by Dean Hannah
On the end of the top and shelf rails, use a marking gauge to mark the center, then pencil over the groove and mark the dowel holes 9/16-in. from the edges. Set the marking gauge stock 3/8-in. from the pin.
To prevent drilling too deep, add a rubber grommet or wrap masking around a 3/8-in. dowel bit 1-in. from the tip to drill the dowel holes.
Use a ruler to mark down the outside faces of the legs to position the rails 9/16-in. from the edge. The top rails are flush with the top of the legs, and the top of the shelf rails are 18-in. from the top of the legs.
On the rails, position 3/8-in. dowel centers in the holes to mark matching holes on the legs, keeping them parallel with the 9/16-in. inset. Assemble without adhesive to check the fit, labeling the joints for final assembly.
Use a hand plane to bevel the edges, except the end of the rails, the top of the top rail and top of the legs; then, sand with 180-grit sandpaper to round over the edges.
Apply wood glue to the holes in the end rails, hammer in the dowels then join them to the legs and check for square. Clamp, remove excess adhesive with a damp cloth and leave to dry.
Apply glue to the holes in the side rails, hammer in the dowels, then join them to the legs, using a wood offcut to protect the surface from marking. Check for square, clamp, remove excess glue and leave to dry.
Position the shelf slats over the rails with the outer ones flush to the legs, securing with glue and 1 1/2-in. brads. Position the top and secure using three 1 1/2-in. angle brackets on the sides and two on the ends using the supplied screws.
Join three 3/4-in. x 9 1/4-in. x 40-in. pine boards edge to edge with glue and dowels spaced 8-in. apart then clamp and leave to dry. Use a table saw or circular saw to trim the 27 3/4-in. width to 24-in.
Before attaching the hardware, use a brush to apply a combined primer and sealer. Finish the trolley with two coats of gloss acrylic enamel using a brush or paint sprayer for a sleek, modern finish.
To apply the casters, make 1/16-in. diameter holes in the front legs, then attach 3-in. locking casters using the supplied screws.
Attach a 17-in.-long bathroom towel rail to the back, positioning it 1 1/2-in. from the top to use as a handle.
© 2012 Reiman Media Group, LLC.