Make the sides and ends


1 Cut the sides (A), ends (B), and tod­dler panel (C) to size [Ma­te­ri­als List]. Lay out the slot cen­ter­lines and the hole lo­ca­tions [Draw­ings 1–3].

2 From 1∕2" ply­wood, make the long-slot jig [Draw­ing 4] and the short-slot jig [Draw­ing 5]. Mark the cen­ter­line, and drill the 21∕2" hole in each end be­fore cross­cut­ting the ends to fin­ished length. Glue up the jigs, in­clud­ing the cleat on each. Trans­fer the cen­ter­lines to the in­side edges of the slots. 3 Mount a 1∕2"-out­side-di­am­e­ter guide bush­ing and a 3∕8" up­cut spi­ral bit in your router. Place the long-slot jig on an end (B), align­ing the cen­ter­lines on the jig and panel, and clamp the jig and work­piece to a backer board [Photo A].

4 Set the router depth stop to plunge the bit 7∕8" be­low the router base. Rout around the perime­ter of the jig open­ing, re­set the depth stop for a 11∕4"-deep cut, and com­plete the slot [Photo A]. Re­peat the process to rout the re­main­ing slots in the ends and sides,

and us­ing the short-slot jig, the slots in the tod­dler panel. Al­ways reg­is­ter the jig cleat against the bot­tom edge of the work­piece. 5 Make the drilling jigs [Draw­ing 6]. Ex­tend the in­dex line over the edge of each jig. Also make a depth stop by drilling a 13∕32" hole through a 3∕4×3∕4" length of scrap. File the cen­ter point off a 13∕32" brad-point bit to pre­vent it from pok­ing through, then drill the holes in the sides [Photo B] and the tod­dler panel.

6 Us­ing the end drilling jig, drill through the ends (B) where marked [Photo C]. 7 Round over the slots and in­di­cated edges and ends [Draw­ings 1–3]. Fin­ish-sand the pan­els to 220 grit.

8 As­sem­ble the sides and ends with con­nec­tor bolts and cross dow­els [Source, Ex­ploded View]. Mea­sure for the bot­tom (D), and cut it to size.

B Side drilling jig Slip the depth stop and drilling jig over the bit, and ad­just the bit so 5∕8" ex­tends past the drilling jig. Align the in­dex line with a hole lay­out mark and drill the holes into each side (A).

Riser Backer A Long-slot jig board

SIDE (In­side face) 47/8" 7" 51¾" 1/8" round-overs 7" 13/32" holes 5/8" deep 1½" 11¾" 7/8" 27" 11¾" 2" 1

1/8" round-overs 13/32" holes 5/8" deep on in­side face 2" 2" 47/8" 7" TOD­DLER PANEL 307/8" 7" 51¾" 6" 3" 207/8" 1¾" R=3" 177/8" 7/8" 2"3" 2" 7" 3

END 1/8" round-overs on all edges 77/8" 29¾" 7" 5" (hole for tod­dler panel) 7" 9/32" hole 2" 11¾" 27½" 11¾" 2" 17/32" 2

Clamp the slot jig to an end (B) and a backer board, edge. Ris­ers cre­ate room for the clamp heads. with the cleat against the bot­tom

C End drilling jig Clamp the ends (B) to the sides (A) with their bot­tom edges flush and the sides in­set Drill holes that in­ter­sect the holes in the sides and tod­dler panel. 1∕4".

½ x ½ x 16" cleat Cut­line Cut­line 2½" hole 14" Cen­ter­line 6½" 6½" 5¾" 8" 4¾" 8"

½ x ½ x 16" cleat Cut­line 2½" hole Cen­ter­line 6½" 15" 8"

SIDE AND END DRILLING JIGS 1" 4" 17/32" END DRILLING JIG In­dex line cen­tered on hole 3" ½" 9/32" hole 3" 6


1" 3" SIDE DRILLING JIG In­dex line cen­tered on hole 3" 7/8" ½" 13/32" hole 3"


2½" hole Cut­line 8" 5¾" 9½"

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