Cage Plans for Adult Chondros

Millwork and Face Frame Assembly

Step 1.  Cut all sheet stock to sizes specified in the cut list.  This is best accomplished using a table saw, but a power saw and a straight edge clamped to the work can also be used.   If cutting melamine, a table saw and special blade must be used or the material will chip badly.  Perhaps a local cabinet shop will mill the material for you.

Step 2.  Using a dado blade on the table saw, or a router with a rabbeting bit, rabbet the inside rear edges of the top, bottom, and two sides.  Make the rabbet 7/16" high X 1/4" deep, as shown below.  The table saw fence has been removed for clarity.  Always use guards on power tools and think safety first!  Only you are responsible for your own safety.

Step 3.  Using a jig saw or a plunge router and template, cut out the holes for the two vents in the back.   Mark the holes using a vent as a guide, and cut out the holes carefully.  The vents should fit snugly and neatly into the holes with no gaps showing.

Step 3a.  Using a biscuit joiner, doweling jig, pocket screw jig, or other joint making tool, make the face frame joints.  Be sure to make nice flush, square joints.  The shorter side pieces fit between the longer top and bottom members.  A biscuit joint is shown below.

Step 3b.  Glue and clamp up the face frame.  Ensure the fame is flat against the clamps, and measure diagonally across both  outside corners to be sure the frame is square.  Let the glue dry overnight.

Step 4.  Route a radius on the outer corners of the frame.  Sand both the back and front sides of the frame, but pay careful attention to getting the front side smooth as it will be a finished part of the cage.

You are now ready to begin applying the interior contact paper to the cage parts. 

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