Cutting day! Ive set up a straight edge to follow, to get as straight of a cut as possible. I have first scored the surface with an 1/8" straight router bit to minimize chipping. I attempted to finish the cut with a jig saw, but found that the blade still wanted to wander a bit, so I finished it with a circular saw, and straightened up the edges afterwards. This was one of those cuts that I thought about for days, and still had surprises!
After cleaning up the edges, Ive attached the rear bull nose, and dry fit the top to make any adjustments.
Getting ready to biscuit join everything back together with glue and underside supports...
Ive put a pipe clamp on the stable end, and used it as an anchor for the strap clamps. Everything needs to be in place before any glue is applied. This will set for a day to cure...
Ive attached the support legs underneath, and have cleaned up the edges and applied the front bull nose. A little sanding helps new blend with old. In this situation, its tough at best to get a perfect fit, but this came out really close! Im happy with the result. Really the only choice to get all the profiles dead on is to do the entire project in the shop from start to finish - this is more of a retrofit situation.
The drawer has been mounted...
Here is a pic of the support legs. Getting the proper angles made the new legs look just like the original.
The polyurethane has been applied, and I will have some final pictures posted shortly!
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