A

Kitchen
Island
By Rob Joseph
Leg Dimensions
Step 1 - Cut the legs (A) slightly longer
than the dimensions given in the material
list. For the thickness we need, the legs
are cut from a piece of 11⁄2"-thick stock,
ripped to 3" wide, as shown in photo A
and A inset.

Leg Glue-Up
Step 2 - Use some wood glue (R) and lots
of clamps to gang a pair of legs together, as
shown in photo B.

We call this project a kitchen island, but after

its completion, we decided that it could be used
in a craft room, sewing room or any place that
requires the ease of a cart that moves around.
C So don't let the title fool you; we're sure you
have some room in your house for this handy
cart on wheels.

Drawer Exploded View

O P
Rails
Step 3 - Cut all the rails (B-G) to the
dimensions given in the material list. Use
the radial arm saw to make the cross cuts
and the table saw to make the ripped cuts, P O
as shown in photo C. Q

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Kitchen Island

D Material List TxWxL

A legs (8) pine 3" x 3" x 31"
B bottom long rails (2) pine 3⁄4" x 2" x 281⁄4"
C bottom short rails (2) pine 3⁄4" x 2" x 131⁄2"
D middle long rails (2) pine 3⁄4" x 11⁄2" x 281⁄4"
E middle short rails (2) pine 3⁄4" x 11⁄2" x 131⁄2"
Rabbeting
F top long rails (2) pine 3⁄4" x 2" x 281⁄4"
Step 4 - e middle and bottom rails,
both long and short, receive a 3⁄8"-wide G top short rails (2) pine 3⁄4" x 2" x 131⁄2"
by 1⁄2"-deep rabbet along their inside top H bottom shelf birch plywood 1⁄2" x 15" x 293⁄4"
edge. Use the router in the router table
with a rabbeting bit adjusted to make I middle shelf birch plywood 1⁄2" x 15" x 293⁄4"
the appropriate rabbet and a fence to add
J top (11) maple 13⁄4" x 13⁄4" x 36"
stability, as shown in photo D.
K center drawer divider maple 3⁄4" x 8" x 153⁄4"
L side drawer guides (2) maple 1⁄2" x 1⁄2" x 12"
E
M upper drawer guides (2) pine 3⁄4" x 3" x 141⁄4"
N top mounting clips (6) pine 3⁄4" x 2" x 2"
O drawer fronts (4) maple 3⁄4" x 515/16" x 1215/16"
P drawer sides (4) maple 1⁄2" x 515/16" x 15"
Q drawer bottoms (2) birch plywood 1⁄4" x 127/16" x 15"

Scrapper Supply List

Step 5 - After the glue has dried in the legs, R wood glue waterproof
use a scraper to remove the squeezed-out
S biscuits (4) #10
glue on each leg, as shown in photo E.
T center drawer divider wood screws (5) #6 x 11⁄4"
U maple buttons (2) 1⁄2"
V brads 3⁄4"
W wood filler

F X American Accents paint (pint) hunt club green satin finish

Y butcher block oil
Z Watco oil natural
AA drawer pulls (4)
BB mounting clip wood screws (6) #6 x 15⁄8"
CC Varathane spray finish
Final Length DD wheels 13⁄4" x 21⁄4" x 23⁄4"
Step 6 - Use the radial arm saw to trim
both ends of the legs to achieve your final
length of 31", as shown in photo F.

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 Kitchen Island

G H I

Witness Marks Ganging Legs Long Rails Mortise Locations

Step 7 - It's always best to make the Step 8 - Start by making mortises for the Step 9 - Mark each leg with a top and
mortises in the legs first, then the tenons long rails. Lay the legs flat with the correct bottom. Refer to the front and side view
on the rails are made to fit. Start by side facing up. Align their bottom edges drawings for the long rail locations. Using
marking each leg right front, left front, so that they are all flush and clamped a square and ruler, mark each mortise
right back, and left back. Arrange the legs together, as shown in photo H. location on the legs, as shown in photo I.
so the best sides are facing out. e inside
faces are where the mortises will be made.
Mark each face to avoid confusing yourself,
as shown in photo G.
J Side View
N J

F G
M
Mortising
Step 10 - Use the drill press with a 3⁄8" L
mortising chisel to make the mortises in
each leg down to a depth of 3⁄4", as shown I
in photo J. If you don't have a mortising
attachment for your drill press, a series
of 3⁄8" holes drilled to a depth of 3⁄4" will
work as well. A sharp chisel will be used to D E
square up the edges.

K
A

H
3⁄4" 3/16"
B

Short Rail Mortise Locations

Step 11 - Lay the legs flat with the short rail 1⁄4"
mortise side facing up and their bottom
edges flush with one another. Clamp all C
4 legs together. Refer to the front and 15/16" A
side view drawings for mortise locations.
Transfer the locations to the legs, as shown
in photo K. 3⁄8"

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Kitchen Island S
1⁄4" M G
N

J 1⁄4"
1⁄2"
F 11⁄2"
5"
L
11⁄2" O P P L

I
E
15/16"
D 1"

K Q
E
3⁄4"

A A
13"
3/16" 121⁄2"
H

1⁄4" B 11⁄2"

15/16"
3⁄8" 7" C
71⁄4"

Front View 21⁄8"

L M N

Mortising Taper Locations Tapering Jig

Step 12 - Use the same mortising chisel the tapers are going to be on the same face high enough, use the band saw and then
and dimensions that were used in step 10 as the mortises. Refer to the front and the jointer (to smooth the cut) to make
to make the short rail mortises, as shown side view drawings for taper locations. the tapers.
in photo L. Transfer locations to each leg, as shown in Step 15 - Use the table saw with the fence
Step 13 - e bottom's of the legs each photo M. and miter gauge to cut the tenons in each
receive a taper on their inside faces. Stand Step 14 - Use the table saw with a tapering of the rails. Refer to the front and side view
the legs up in the final order. Notice how jig to make each taper, as shown in photo drawings for tenon dimensions. Make a
N. If your table saw blade does not rise

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 Kitchen Island

O P Q

Shoulder Cuts Cheek Cuts Shelving Dimensions

test tenon in some scrap wood to assure Step 16 - Lay the rails flat against the table Step 17 - Sand all the rails and legs through
proper fitting. Start off by making the saw surface, and make the cheek cuts, 220-grit sandpaper.
shoulder cuts, as shown in photo O. Pass nibbling away the material with each pass, Step 18 - Cut the middle shelf (I) and the
each piece through the blade several times, as shown in photo P. bottom shelf (H) to the dimensions given
moving the piece further from the fence in the material list. Use the table saw to
with each pass to remove the remaining make the cuts, as shown in photo Q.
material, as shown in photo O inset.

R S T

Shelving Notch Layouts Jig Sawing Groove For Mounting Clips

Step 19 - e shelves have notches cut out Step 20 - Use a hand-held jig saw to the table saw with a stacked dado blade
of their corners to fit around the legs. Dry- remove the notches in the shelves, as shown to make the 1⁄4"-wide by 1⁄4"-deep groove
fit the rails and legs together, and measure in photo S. 1⁄2" down from the top edge, as shown in
around the inside corner of each leg to Step 21 - e top rails; both long and short, photo T.
get the notches' dimensions. Transfer the receive a groove near their top inside edges. Step 22 - Cut the upper drawer guides (M)
dimensions to the shelves, as shown in e groove is used with top mounting clips to the dimensions given in the material list.
photo R. (N) to fasten the top to the frame. Use ese guides connect to the front and back

U V W

Making Biscuit Slots Top Dimensions Top Glue-Up

top long rails with #10 biscuits (S). Refer Step 23 - Cut the top (J) to the dimensions
Step 24 - Glue and clamp the top pieces
to the front view drawing and exploded given in the material list. Cut the top's with their side grain face up, as shown in
view drawing for their locations. Mark the length about 1" longer than what's given photo W.
biscuit slot locations in each piece, and use in the material list. Use the radial arm
the biscuit joiner to make the #10 slots, as saw to cross cut the pieces and the table
shown in photo U and U inset. saw to make the ripped cuts, as shown in
photo V.

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Kitchen Island

X Y Z

Center Divider Notches Mounting Clips Drawer Front Rabbets

Step 25 - Cut the drawer divider (K) to Step 26 - Cut the side drawer guides (L) to are pre-drilled and countersunk in their
the dimensions given in the material list. the dimensions given in the material list. centers for the wood screws (BB), as shown
e divider is notched to fit around the Step 27 - Cut the top mounting clips (N) in photo Y inset.
top front and back long rails. e notches to the dimensions given in the material Step 28 - Cut the drawer fronts (O), the
measure 3⁄4"-wide by 2"-long. Transfer each list. e clips are made with a 1⁄4"-wide by drawer sides (P), and the drawer bottoms
notch to the divider's top edge, as shown 1⁄4"-long tenon. Use the router in the router (Q) to the dimensions given in the material
in photo X. Remove the material using the table with the fence to make the rabbet in list. e drawer fronts receive a 1⁄2"-wide by
hand-held jig saw. a piece of stock long enough to make the 3⁄8"-deep rabbet on both their inside ends.
6 clips, as shown in photo Y. e clips Use the table saw with a 1⁄2" stacked dado
AA BB CC

Drawer Side Grooves Drawer Front Grooves Top Edges Rounding Over
blade raised to a height of 3⁄8". Use a miter 1⁄4" stacked dado blade. e grooves start Step 31 - Sand the top through 220-grit
gauge to keep the fronts square as you run 1⁄4" up from their bottom edges, as shown sandpaper. Cut the top down to its final
them over the blade, as shown in photo Z. in photo AA. length of 36". Use a round-over bit in the
Step 29 - e drawer sides’ inside surface's Step 30 - e drawer front’s inside surface router to ease the edges of the top. Both
receive a groove along their bottom edges receives the same groove along its bottom top and bottom edges get rounded over, as
to house the bottom. Make the 1⁄4"-wide by edge, except it’s 3⁄8"-deep, as shown in shown in photo CC.
1⁄4"-deep groove with the table saw and a photo BB. Sand all the drawer parts
through 220-grit sandpaper.

DD EE FF

Top Rails Button Locations Middle Shelf Screw Locations Partial Glue-Up
Step 32 - e center drawer divider is held edge. Countersink to a depth to hold a 1⁄2" Step 34 - Assemble the project frame in
in place with two wood screws (T) through maple button (U), as shown in photo DD. two halves. Clamp and glue two legs with
the top long front and back rails and three Step 33 - Drill 3 evenly spaced countersunk the top long rail, middle long rail, and
wood screws (T) centered and evenly screw holes in the center of the middle bottom long rail. e groove in the top rail
spaced through the middle shelf. Locate shelf's bottom side. Only countersink to a and the rabbets in the middle and bottom
the center on the long rails, and drill a 1⁄2" depth to allow the screw head to sit flush rails face toward the top, as shown in photo
countersunk hole 1" down from the top with the wood, as shown in photo EE. FF. Check for square.

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 Kitchen Island

GG HH II

Frame Assembly Dry-Fitting Drawers Fastening Middle Shelf

Step 35 - Once the two halves have dried, Clamp the entire frame assembly together side and up and down, as shown in photo
keep one set of legs flat against the table. and check for square, as shown in photo HH. Make any necessary adjustments if
Glue in place the short rails and upper GG inset. the drawers don't move freely.
drawer guides with biscuits in one half of Step 36 - Dry-fit the drawers together. Step 37 - Remove the drawers and fasten
the leg assembly. Place the middle shelf in Place the center divider into its final the middle shelf to the top rails with 3⁄4"
position now, as shown in photo GG. Glue position. Slide the drawers in the openings.
the other leg assembly onto the short rails Check that the clearance is enough side to
and upper drawer guides with biscuits.

JJ KK LL

Hardware Pre-Drilling Drawer Assembly Mounting Clips Screw Locations

brads (V), as shown in photo II. Cover the hardware in place, as shown in photo JJ. Step 40 - Place the top, with the top side
nail heads with wood filler (W). Sand the Step 39 - Assemble the drawers together down, and center the frame assembly on
wood filler flush when dry. with some wood glue in the rabbets and the top. Place the top mounting clips into
Step 38 - Pre-drill in the center of the 3⁄4" brads (V), as shown in photo KK. position evenly spread around the top.
drawer fronts the screws that will hold your Mark the clip screw locations with an awl

MM NN OO

Pre-Drilling Tape Off and Paint Applying Finish

through the screw holes in the clips, as Step 42 - e entire project is painted top surface is not painted between the two
shown in photo LL. except the top, drawers, drawer divider, side drawer guides and the front and back
Step 41 - Remove the frame assembly and upper drawer guides, side drawer guides long rails. Use some tape to prevent from
pre-drill into the top for the 15⁄8" mounting and maple buttons. Paint the project a color painting on these areas.
clip wood screws (BB), as shown in of your choice, or use the color we used (X),
photo MM. as shown in photo NN. e middle shelf's

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Kitchen Island

PP QQ RR

Side Drawer Guides Fastening Center Divider Attaching Top and Wheels
Step 43 - Finish the painted portion of the Step 45 - Center and attach the center Step 47 - Attach the wheels (DD) with
project with a few coats of the spray finish drawer divider with the wood screws (T) four screws centered on the bottom of each
(CC), as shown in photo OO. from under the middle shelf and through leg, as shown in photo RR inset.
Step 44 - Remove the tape from the middle the long front and back rails, as shown in Step 48 - Apply a coat of butcher block oil
shelf. Glue and clamp in place the side photo QQ. (Y) to the top. Add a few coats of Watco
drawer guides so that their inside edges are Step 46 - Place the frame assembly back oil (Z) to the center divider, drawer fronts,
flush with the inside edges of the legs, as onto the top, and fasten the top to the drawer sides on their outside surfaces only,
shown in photo PP. frame through the mounting clips with the and the maple buttons. Attach hardware
wood screws (BB), as shown in photo RR. (AA) to the drawer fronts. WW
Exploded View

N
J G

N F N
M
L
M K
D E F

G
U
I
A

T D
C
L
E
B

A H
A

B
C
A

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