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Because 4 of the 6 storage cabinets are 7 high, I am making the face frames full height with a cross member located at a shelf.  Because of the full height, I need to use mortise and tenon joinery. This type of joint is much stronger than other joints, and provides for a lot on internal glue space. Here are picture of my mortise and tenon joints, and one of the face frames being clamped up.  I have 4 to do, plus 2 smaller ones...




While the face frames are setting up, Ive decided to put a support member on the taller cabinets at the stationary shelves. I intentionally left a 3/4" recess on the face of the shelf, and I will fill it with an oak strip. This will strengthen the shelf, as well as give a secure anchor point for the face frames.

Where to start with the details of the PBB? As I stated in the first post, I elected to make my PBB in two parts so that I could configure it to handle situations I knew I would encounter. I guess I should start with the basic structure of the bench.

I constructed the frame out of good old southern yellow pine. I bought 2x8s and milled it to get the sizes I needed. I chose 2x10s because they are made from larger trees and are a better grade than 2x4s and 2x6s. The thickness was a little under bit 1.5” after jointing, but I had a better surface. The corner posts were glued up to get 4x4s.

This is the frame of the 36”x72” module. The slats on the bottom support a piece of .75” plywood. The slats on the top only support a piece of .25” hardboard, which is a dust shield. I may eventually enclose the bottom of the modules, and I don’t want them filling with saw dust. There are four 5” heavy duty swivel casters. The frame of the 24”x72” module is constructed the same way.