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prep parts and Work Area before starting
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Make sure you are working on a sturdy, fl at work surface
that will not scratch or damage the parts while handling.
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Lightly sand and deburr the part edges if needed.
Recommended Tools for Chest Construction
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Wood Glue
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12" Bar Clamps (2-3)
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36" Bar Clamps (4)
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#2 Philips Screw Driver
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Rubber Mallet or Hammer
Please Note: If you are not going to start building the chest right away, you will need to weight down the parts. The parts are
unfi nished and can warp if left in the box for extended periods of time. Gerstner is not responsible for replacing warped parts
15 days after receipt.
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It is recomended to dry fi t (construct without glue) the
parts to familiarize yourself with the assembly process.
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Electric Drill
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Router (Optional)
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3/16" Roundover Bit
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100 and 150 Grit Sandpaper
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Scale or Ruler
2609 Chest
DIY Kit
Instruction Manual
•
90 Degree Square
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Choice of Stain/Finish
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3/32" and 3/16" Drill Bits
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Paraffi n wax
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Drawer bead bit if desired
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Table of Contents
Related Manuals for Gerstner 2609
Summary of Contents for Gerstner 2609
- Page 1 Please Note: If you are not going to start building the chest right away, you will need to weight down the parts. The parts are unfi nished and can warp if left in the box for extended periods of time. Gerstner is not responsible for replacing warped parts...
- Page 2 Chest Sides Partition assembly Install the Lid Slide Plate w/nails on each side. The top partition has a tongue along the front edge. Glue the small partitions with the solid wood cap facing the front edge of the top partition. It is shown upside down during assembly.
- Page 3 Box Assembly Top assembly (continued) Locate the box top pieces and assemble as shown. Continue to assemble the chest and check to make sure all the drawer slides line up with each other. If you install the short partitions incorrectly the drawers will not work.
- Page 4 Front Lid Assembly Drawer Fronts: knob hole machining (continued) Mark the knob location on the inside of the drawer face. Clamp the front lid at the top and bottom at each end rail. Drill a 3/16'' hole at the desired location. Using a 7/16 drill, countersink or forstner bit, countersink for screw head.
- Page 5 Fit the drawers to the box making sure that the gaps between the drawers are uniform. Because all wood swells under certain conditions, a drawer fi t with minimal clearance is not recommended. (Gerstner recommends 1/32"-1/16" gap on all sides of the drawer.) Final sand all parts of your chest to desired grit.
- Page 6 Staining & Finishing Install plunger pins Stain and fi nish the parts as desired. Gerstner stains Locate the plunger pin, spring and 2 stainless steel washers. and then applies 1-2 coats of a lacquer sealer and then 1-2 top coats of lacquer. (Make sure to use a style fi nish that you are comfortable working with.)
- Page 7 A 50/50 mix of white glue and water can be used for felt Centered installation. We recommend Gerstner Whew Glue for all felt applications, as it holds reliably, yet easy to replace if you ever need to re-felt in the coming years.
- Page 8 Parts List — DIY KIT STyle #2609, MasterCraftsman Chest • Chest Parts List Quantity 1 ¼ x 15 ......2 pcs •...
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