This a quick blog pertaining to how I made a puzzle board. The materials are a 1/2 sheet of cherry cabinet grade 1/4" ply...well, the stuff with the mdf core. And some 4/4 walnut.
I believe the sheet was cut down to two 24x36" pieces. I ripped some walnut 3/4" x 1" for dividers. Thus the space for the drawers will be 1"tall. In the picture below I'm gluing (weighting) the dividers in place. Precision is a must, otherwise you'll have wonky sliding drawers.
The sides are walnut with a big rabbet on each edge, I left the rabbet a bit deeper than the thickness of the ply, then I can plane it perfect. So, one inch between the rabbets, and a hair over 1/4" on the two rabbets.
Above I glued the bottom. Then, I glued the top in the other rabbets. This is what it looks like glued. I left the sides long initially, then used a scrap to mark the correct length.
This is where I had to remove a bit of the side by hand so the drawer would close.
I then cut this piece in half and proceeded with my drawers.
The drawer sides are just half inch stock with a rabbet the thickness of the ply. The drawer bottom is glued flush.
Now, I planed the sides flush to the cherry ply, the I added some 1/2" walnut to the perimeter - as a fence of sorts. The customer wanted an opening on the right side.
Plane the edges all flush, and soften all sharp edges with a block plane and sandpaper.
Finish was dewaxed shellac (zinsser sealcoat), aerosol satin lacquer, and Howards feed'n'wax.
It turned out well, and my friend seems to really enjoy it.