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Finish product first. The project is made with less than 1 sheet of 5' by 5' 1/2" baltic birch plywood. I designed the corgi in AutoCAD 3D to make sure everything would mesh together correctly. I then laid out everything in 2D on 8.5" by 11" paper sections with overlaps so that I could print out 1:1 scale and simply tape the pieces together to create my cutting templates.
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The first step was breaking down the 5' by 5' sheet to reduce waste. I laid out everything in CAD before hand to figure out best use of material (see my website's free plans if interested).
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Once all templates were printed out and pieces cut to rough size I used spray adhesive to attach them together.
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Everything was cut as close as possible to the line using my band saw.
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I used the strip sander when I could as it leaves a nicer edge at half the time of the spindle sander. I sanded to the line.
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Anything the strip sander could not get I used the spindle sander to get.
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The larger pieces had to have several sheets of standard printer paper lined up and taped together.
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The large pieces were cut out 95% on the bandsaw and 5% with the jig saw where the bandsaw was impossible.
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This was the only piece that is duplicated so I clamped down the finished first side and traced it out with a pencil and repeated the process.
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The jig saw was the best way to cut out shapes to minimize waste.
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I glued and tacked on with brads 4 cleats to help support the shelf in the center should anyone put something heavy on him (like a tv).
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I sealed the dog with water based polyurethane.
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Step 1 in assembly was to put the front legs on with both sides.
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Next the back legs.
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Then the center (main) piece.
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After the 2 inside dividers where placed the middle shelf was knocked into place.
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Top front and back dividers where placed and then the face and nose.
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I butt nailed the top shelf where I previously attached cleats to the center 2 vertical pieces.
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The top shelf assembly then slips into place.
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It gets held in with a couple brads in each side.
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To keep the face and nose from racking or being taken off I fired a few brad nails in the bottom.
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With that I can call this Corgi complete.
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Roll over... Good boy!
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  • HOME
  • Videos / Build Articles
    • Project Builds
    • Shop Projects
    • Kids Projects
    • Gift Idea Projects
    • Around The House Videos
    • Viewer's Comments Videos
  • Plans / CAD FILES
    • Project Build Plans
    • Shop Project Plans
    • Kids Project Plans
    • Gift Idea Project Plans
  • Viewer Submissions
    • Viewer's Submissions - 2017
    • Viewer's Submissions - 2018
    • Viewer's Submissions - 2019
    • Viewer's Submissions - 2020
    • Viewer's Submissions - 2021
    • Viewer's Submissions - 2022
  • T-Shirts
  • Contact