It all comes down to a man, a drill, and the product of ten weeks of work-- NO mistakes permitted! The drilling phase of the construction process was both exhilarating and terrifying. Prior to the drilling phase, the highest pressure point occurred while inserting the cabinet into the core. Both pieces were "finished" and the joints were so tight that four heavy-duty clamps, innumerable towels and a glass of wine were all required to bring things together. The glue timer was nerve-wracking – fifteen minutes to get things together or bust. As the clamps were slowly tightened, the wood creaked like the hull of a ship in a storm. Thankfully, everything worked out beautifully.

The pictures above and below were taken during the drilling phase and highlight the jig constructed and used for drilling evenly from corners at a 90º angle without the use of a drill press. The final hardware is also featured within the images. Stainless steel rods were cut to length by Justin at Coyote Steel and the precision custom threading was completed by Ken at Welch's Machine Works. A special thanks to Ken for rushing this job and taking the extra time to make sure the flange/weld nuts and the threaded rods fit together seemlessly. Other than the six screws securing the horizontal and vertical pieces of the MDF core, the exposed hardware is the only hardware used in the entire piece. All flange/weld nuts were pressure fit.

Note the photograph above where 1/32" spacers were added to one side of the jig for drilling the shallow holes on the bottom of the keystone. These were added because the width of the keystone and cabinet differed by 1/16". Also shown below, is the drill bit banded with green tape. The tape indicates the limited depth to drill on the keystone since the holes could not puncture through the wood.