Instruction Manual for 60” Oak desk and hutch

Materials

30’ 1x10” solid red oak $150.00

2 ¾”x4’x8’ oak plywood $90.00

2 ½”x4x8’ oak plywood $70.00

1 ¼”x4x8’ oak plywood $20.00

3’ 1x12” solid red oak $18.00

20’ 1X2” sold red oak $40.00

1 Box 1 ¼” drywall screws $3.00

8 Pairs of drawer roller guides $40.00

1 Pair keyboard roller guides $20.00

1 Box of 2" drywall screws $2.00

1 Quart sanding sealer $5.00

2 Quarts satin finish polyurethane $10.00

12’ 1x2” pine

Optional

2 2 ½” diameter halogen lights with wire.

1 Small push button switch (radio shack has them)

Instructions

Desk Construction

1. Start by cutting desktop from a ¾”x23 ¼”x58 ½” Oak plywood.

2. Cut Dados on one side of top ¼” from each end and 171/4” in from each end.

4. Cut one of the 1x2” oak boards to 60” with 45 degree angles on each end and two 1x2”x24” red oak with 45 degree on one end only.

5. Glue 1x2” strips to desktop so that the ¾” edge is perpendicular to the top.

6. Cut the leg sides from ¾” oak plywood 23”x28 ¼”.

7. Cut cleats to fasten the sides and top together using the 1x2” pine, cut 4 strips 22” long and two strips 16” long.

8. Using a 1/8” countersinking drill bit, drill holes aprox 6” apart through the pine strips. Then glue and fasten with ¼” drywall screws to the bottom side of the desktop against the inside of each dado.

9. Insert the side pieces into the dados and then glue and screw sides in place. (Be sure to screw from the pine cleat side so that no screw holes will show from the outside.

10. Cut two ¾”x6”x16” braces from the oak plywood and glue and screw across the bottom back of the sides. The braces should set ¼” from the outer edge.

11. Cut two ¾” x2” x 16” braces from the oak plywood and glue and screw across the front bottom of the sides. These should be set 7/8” in from the front edge to allow the drawer fronts to rest against.

12. Cut four ¾” x 1 ½” x 16” braces from the oak plywood to be used for the center braces and drawer stops, set aside for later.

13. Cut two ¾” x 1” x 16” braces from the oak plywood to be used for the tray stop, set aside for later.

Drawer Assembly

14. Cut the drawers out of the ½” thick plywood, dimensions of bottoms are 20 1/4”x 15”. Cut 8 of these.

15. Cut four ½”x11”x21” for the bottom drawer sides, four ½”x6”x21” for the middle drawer sides and four ½”x3 ½”x21” for the top drawer sides.

16. Cut two ½” x 11x14 ½” for the bottom drawer backs and two ½” x 11” x 14” for the bottom drawer fronts.

17. Cut two ½” x 6” x 14 ½” for the middle drawer backs and two ½” x 11”x 14” for the middle drawer fronts.

18. Cut two ½” x 3 ½” x 14 ½” for the top drawer backs and two ½” x 3 ½” x 14” for the top drawer fronts.

19. Make a ½” wide dado ¼” from one edge down each of the drawer sides for the bottom piece to fit into. (dados should be cut on opposing sides). Also cut dados ¼” from the edge of the drawer front and back pieces.

20. Cut one more dado across the sides for the back piece to fit into. The front drawer pieces should be butt against the inside sides.

21. Glue and nail with 1 ¼” finishing nails to assemble the drawers. Two finish nails on each edge should be sufficient. (be sure to drill pilot holes so you don’t split the wood).

22. Screw the gliders onto the sides of each drawer so that they are centered in the middle.

Final desk assembly

23. Slide the bottom drawers in place and using a 1/8” thick strip of wood as a shim, place the shim under the front bottom of the drawer rest. Position the back so it is level with the front of drawer and then mark and mount your drawer gliders to the desk sides. Repeat for other side.

24. Using the 1 ½” x 16” piece of plywood you cut earlier, cut and glue a piece of the 1x2” pine to each end and place a drywall screw through the middle of the pine cleat to hold it in place while the glue dries. Then drill two more holes through the opposing edge and screw to sides of the desk so that the drawer rests 1/8” below it and is also 7/8” inset for the drawer to rest evenly against when closed.

25. Repeat procedure 23 and 24 above for the remaining drawers.

26. Before installing the top two slide out trays, make the front pieces for these using 1x1 ¼” x 16” oak. Router the edges with ¼” rounding bit and then glue to the front of the trays.

27. Mount trays into desk following procedures 23 and 24 above.

28. Cut the solid oak drawer fronts to size and round edges with ¼” rounding bit. Using a ¾” 45 degree straight edge bit, route the drawer pull edges on one side of each drawer front.

29. Align drawer fronts to desk drawers making sure the pull edges are position correctly and then drill and screw in place from inside drawer.

30. Cut and install keyboard tray from ¾” oak plywood, tray should be 16”x 24” aprox. Use keyboard gliders found at Home Depot.

31. Apply wood tape to front edges of legs and around keyboard tray. Sand all pieces to a smooth finish.

Hutch Construction

The hutch is constructed from the 30’ of 1x10” solid oak.

Cut all pieces according to dimensions in picture, make dados as shown and assemble with wood glue.

Finish desk with polyurethane and then use 0000 steel wool and beeswax to produce smooth finish.

Add lights by drilling 2 1/8” holes in top of hutch about ½” deep. Using a long ¼” drill bit, carefully drill holes for the wire to run out the back of the hutch. Mount the push button switch on either side of the desk just above the keyboard tray for easy access.