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prep parts and Work Area before starting
•
Make sure you are working on a sturdy, flat work surface
that will not scratch or damage the parts while handling.
•
Lightly sand and deburr the part edges if needed.
Recommended Tools for Chest Construction
•
Wood Glue
•
18" Bar Clamps (2-3)
•
#2 Philips Screw Driver
•
Rubber Mallet or Hammer
*Caution: We use veneer plywood on the top of this case. The plywood gives the box stability through everchanging conditions of humidity.
Please note that you must exercise great care when sanding the top surface. The veneer is .010" thick and excessive sanding on the top can
cause a sand-thru, to the plywood core below the veneer. We suggest you sand the solid wood just enough to meet the surface of the veneer.
1600 Tote Case
•
Electric Drill
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Router (Optional) with flush cut bit
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1/8" Roundover Bit
•
100 and 150 Grit Sandpaper
DIY Kit Instruction Manual
•
It is recomended to dry fit (construct without glue) the
parts to familiarize yourself with the assembly process.
•
Scale or Ruler
•
90 Degree Square
•
Choice of Stain/Finish
•
3/32" and 3/16" Drill Bits
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Table of Contents
Related Manuals for Gerstner 1600 Tote Case
Summary of Contents for Gerstner 1600 Tote Case
- Page 1 1600 Tote Case DIY Kit Instruction Manual prep parts and Work Area before starting • • Make sure you are working on a sturdy, flat work surface It is recomended to dry fit (construct without glue) the that will not scratch or damage the parts while handling.
-
Page 2: Bottom Assembly
Bottom Assembly Clamp box as shown and wipe off excess glue. Check assembly for squareness with 90-degree square. Allow time for glue to dry before handling and double check to make sure the bottom is flush with the frame Locate the box sides as shown. You will notice that each components. -
Page 3: Top Assembly
Top Assembly Tray Assembly Lay top parts out. Add glue to the parts for assembly. Next, assemble the tray as shown. The tray bottom is 1/8" hardboard (or birch plywood in some kits) and is installed in the 1/8" groove cut in the tray parts. Please note the tray bottom will not be flush with the tray frame parts. -
Page 4: Hardware Installation
Round over edges with hand sanding block to prep the 3/32" drill bit (excluding the top lid tack). chest for corner hardware. OPTIONAL: Gerstner typically rounds over exterior edges to soften the feel of the product. This can be Rubber bumpers attach with the bottom corner hardware. - Page 5 Apply top coat to parts as desired and let finish fully a few hours to dry. cure before handling. Install the Gerstner nameplate where desired. We typically place the nameplate on the front for this style of chest. After installation, remove the protective...
- Page 6 • Birch plywood bottom ..... .1 We would love to see your Gerstner Workshop • Tray support rails – poplar ....2 project pictures! Post and visit us at: •...
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