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Author Topic: ATTN: Woodworkers - How do I make a butt joint perfectly flush?  (Read 3969 times)

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javeryh

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ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« on: December 12, 2005, 10:35:22 am »
This is a (hopefully basic) woodworking question...

My control panel is a flat piece of 3/4" plywood and I want to attach another piece of 3/4" plywood in the front forming a corner but I'm not sure how to go about it.

RetroACTIVE

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #1 on: December 12, 2005, 11:08:16 am »
Is the bullnose already cut?

If not.. you could use glue and dowel...

Clamp the sides together.
Drill through the side (where the bullnose will be) and into the control panel.
Cut dowels to approximate length.
Un-clamp the the assembly.
Add glue and dowels... clamp it back together
Let it dry
Route off the bullnose...

... it would then be perfectly mated with the control panel.
Happy Gaming!

mccoy178

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #2 on: December 12, 2005, 03:07:20 pm »
I personally would recommend a Brad Nailer.  I bought a cheap 18 gauge from Harbor Freight for about $20 tops.  That and wood glue.  I also use a small block with glue and brad nails on the inside to secure it.  Check out my OSU cabinet #2 http://www.ohiostate.photosite.com/ScottsOSUcabinet/.  I just posted new pics last night showing how I built the CP box.






javeryh

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #3 on: December 12, 2005, 04:04:52 pm »
Is the bullnose already cut?

If not.. you could use glue and dowel...

Clamp the sides together.
Drill through the side (where the bullnose will be) and into the control panel.
Cut dowels to approximate length.
Un-clamp the the assembly.
Add glue and dowels... clamp it back together
Let it dry
Route off the bullnose...

... it would then be perfectly mated with the control panel.

javeryh

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #4 on: December 12, 2005, 04:06:39 pm »
I personally would recommend a Brad Nailer.

mccoy178

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #5 on: December 12, 2005, 04:51:10 pm »
You can brad nail from the outside and have a tiny hole.  You wouldn't even need to patch it, but if you wanted to, fust a little filler would hide the hole.  The key with the brad nailing is to use the glue.  I bought a pack of fifty cheap brushes and spread the glue across the seams with them.  The blocks on the inside are just added security.  I just think the dow rods would be difficult and over the top for this application.  I built both boxes in about three hours.

Doughbroz

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #6 on: December 12, 2005, 05:47:31 pm »
20 bucks is a good price for a brad nailer--provided one already has the air compressor to run it.

SirPoonga

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #7 on: December 12, 2005, 06:55:08 pm »
I would, with the tools I have (the poorman's way), lay out the pieces like in the attached pic.  The blue box is a flat surface. Use 1x1 strips to connect edges like mccoy.  Do the same thing as in the pic.  Then sand the joint until smooth.

You might be able to use a corner clamp or a corner of a room to hold the vertical piece in place until screwed.
« Last Edit: December 12, 2005, 06:58:00 pm by SirPoonga »

mccoy178

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #8 on: December 12, 2005, 06:58:21 pm »
Harbor Freight is an excellent source for tools on the cheap.  I also bought my air paint can(forgot name), from there for twenty bucks.  Awesome junk tools for our purposes.

www.harborfreight.com

dema

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #9 on: December 12, 2005, 09:04:53 pm »
Huh huh. You said butt and flush in the same heading...


Just kidding. Anyway. I did the exact same thing with my panel. What I did was wood glue the surface piece on top of the front piece and once that dried a little bit I then marked out a series of drill points where three-hole L brackets would go (the longer ones). I attached a bunch of brackets from one end to the other which gave it a ton of support. Substituting a piece of wood for the brackets would definitely serve the same purpose, but with a rotating panel I didn't have the clearance to do it that way.

Once they were attached with glue and brackets I applied wood putty to the seam between the two and sanded the top piece down so the edge was rounded over well. I then added the vinyl over it a few weeks later. It turned out really well.

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #10 on: December 13, 2005, 07:39:38 am »
I think a pocket hole jig would fit the bill nicely.

http://www.homedepot.com/prel80/HDUS/EN_US/jsearch/product.jsp?pn=154554
« Last Edit: December 13, 2005, 07:41:33 am by Santoro »

Lilwolf

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #11 on: December 13, 2005, 10:52:02 am »
I got a pocket jig and haven't had time to perfect it...

but my first few tried I didn't get a perfect edge.  I keep planning on trying again.  Wood scrap is a necessity for getting things like this perfect.


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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #12 on: December 13, 2005, 02:01:38 pm »
I love my pocket jig.  I have made many a thing out of oak with it.  You would have to use some fairly short screws in that corner though.

Avery

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #13 on: December 13, 2005, 06:17:26 pm »
I would do something like Sir Ponga suggests, only I'd use two rectangular pieces of plywood to act as supports.  Set one piece and the two support blocks on edge so it looks like the greek letter pi, clamp that together, rotate 90 degrees and clamp your other piece to the front.  Your work surface should force them to be just about flush.

Just make sure not to overglue or you'll never get your supports back out.
Avery

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Re: ATTN: Woodworkers - How do I make a butt joint perfectly flush?
« Reply #14 on: December 13, 2005, 08:09:58 pm »
Are using the special screws? 

I got a pocket jig and haven't had time to perfect it...

but my first few tried I didn't get a perfect edge. I keep planning on trying again. Wood scrap is a necessity for getting things like this perfect.