H.Gerstner & Sons 35B User manual

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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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H.Gerstner&Sons
Style35BKitChests
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35BChestPartsandHardware
Solidwoodtop
Solidwoodback
Right&leftsides
Birchplywoodbottomwithcap
Frontlidstopstrip
(14)Mapledrawerslides
Birchplywoodsmallpartitionwithcap
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(8)Boxcornersw/screws
(4)Rubberbumpersw/screws
(1)Lockw/keyandmountingscrews
(2)Lidslideplatesw/nails
(2)Steelrodlidpins
(1)Nameplatewithbrads
(3)FinishNails
(2)FeltDots
35BDrawerParts:(7Drawers)
(4)15/8''highshortdrawerfronts(oak)
(1)15/8''highlongdrawerfront(oak)
(2)2''highlongdrawerfronts
(5Pair)19/16''highright&leftsides(poplar)
(2Pair)115/16''highrightandleftsides(poplar)
(4)19/16''highshortbacks(poplar)
(1)19/16''highlongback(poplar)
(2)115/16''highlongbacks(poplar)
(4)Smallhardwooddrawerbottoms
(3)Largedrawerbottoms(masonite)
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Recommendedtools
#2Philipsscrewdriver
Woodglue
RubberMallet/Hammer
100and150gritsandpaper
Routerwithflushcutbearingbit
3/16''roundoverbearingbit
(4)24''clamps
Electricdrill
Drawerbeadbitifdesired
Paraffinwax
90degreesquare
YourChoiceofStain/Finish
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PleaseNote:Ifyouarenotgoingtostartbuildingthechestrightaway,youwillneedtoweightdown
theparts.Thepartsareunfinishedandcanwarpifleftintheboxforextendedperiodsoftime.
Gerstnerisnotres
p
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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35BDIYAssemblyInstructions
Partsprepbeforestartingthejob
Makesureyouareworkingonasturdyflatworksurfacethatwillnotscratchordentyourpartswhilehandling
them.Lightlysandthepartedgessothattheyarefreefrombursandsplinters.Alwayscleanexcessglueoff
ofyourpartswithadampragasthiswillmakefinalsandingandfinishingafterassemblyeasier.
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ChestSides
1.Installthedrawerslides:Glue(5)mapledrawerslidesinthegroovesontheside.Alignthemaple
drawerslidesothespraypaintedblackedgeoftheslideisfacingtowardthebottomedgeoftheside.The
mapledrawerslidesshouldbealigned11/2"fromthefrontedgeoftheside.Themapledrawerslidesarea
snugfitinthegrooveandalittleextrasanding/fittingmaybeneeded.Usegluelightlyandusea
hammer/rubbermallettotaptheslidesintothegrooves.
2.Installthelidslideplate:placetheLidSlidePlateintotherecessedgrooveatthefrontedgeofthe
side.Alignthelidslideplatesothecutoutontheplateislinedupwiththegrooveintheside.Beforenailing
intoplace,slidethesteelrodlidpinbackandforthinthegroovetomakesurethattheLidSlidePlateis
properlyaligned.Tapthe2nailsintothepredrilledholesintheLidSlidePlate.
3.Repeattheprocessfortheotherside.
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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DrawerPartition
Glue(2)MapleDrawerSlidesinthegroovesoftheBirchPlywoodSmallPartitionwithCap.Alignthe
mapledrawerslidesothepaintedblackedgeoftheslideisfacingtowardthebottomedgeofthePartition.
Themapledrawerslidesshouldbealigned1/2"fromthefrontedgeofthePartition.Ifthemapledrawer
slidesaretightinthegroove,usearubbermallettotaptheslidesintothegrooves.Flipthepartitionoverand
repeat.
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TopAssembly
ThetopedgeoftheBirchPlywoodSmallPartitionwithCaphasa3/16"notch.Gluethetopedgeof
thepartitionintothecentergrooveonthetop.Thepartitionshouldbe1"fromthefrontedgeofthetop.Use
asquaretomakesurethepartitionwillhangstraightinthechest.
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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BoxAssembly
ItisrecommendedthatyoupreassembletheboxWITHOUTgluetofamiliarizeyourselfwiththeprocess.
1.Laythesideofthechestonyourworksurfaceandalignthefrontedgeofthetopwiththesideof
thechest(thefrontedgehasthelockslotgroove).Gluethetopintothetopgrooveoftheside.
2.Gluethebackintothegrooveontheundersideofthetopandalsointhegroovealongthebackof
theside.
3.Gluethebottomintothegrooveatthebottomoftheside.
4.Onceyouhaveallofthepieceslinedup,addgluetothepartsandthenplacetherightsideontop
andaligneachpartwiththegroovesintheside.Usearubbermallettotapthesideontotheotherparts.
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5.Clamptheboxatthetopandthebottom,andchecktomakesurethattheboxissquare.
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6.Usethefinishnailstonailthebacktothebottomofthechest.Makesurethebottomofthechestisflat,
notbowedinoroutfromyourclampsbeforeyounailthebacktothebottom.Youcanuseanailsettosetthenail
flushwiththewood.
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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DrawerAssembly
1.Alignthetopedgeofthedrawerfrontwiththetopedgeofthedrawerside.Gluethedrawerfronttothe
drawerside.
2.Alignthetopedgeofthedrawerbackwiththetopedgeofthedrawerside.
3.Slidethedrawerbottomintothebottomgrooveofthedrawerfront,backandside.(Thedrawerbottom
floatsinthegroove,donotglueintothegroove).
4.Onceyouhaveallofthepieceslinedup,addgluetothepartsandthenplacetheoppositedrawersideontop
andaligneachpartwiththegroovesintheside.Usearubbermallettotapthesideontotheotherparts.
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5.Clampthedraweratthefrontandbackofthesidesandchecktomakesurethatthedrawerissquare.Once
thedrawerissquare,letthedrawersituntilthegluedries.
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6.Repeatfortheremainingdrawers.
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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FrontLidAssembly
1.Aligntheoutsideedgeoftheendrailwiththeoutsideedgeofthebottomrailofthefrontlid.
2.Putthecenterpanelofthefrontlidinthegrooveoftheendrailandthebottomrail.Thecenterpanelfloats
inthegroovesofthefrontlid,donotgluethepanelintoplace.(Thecenterpanelisundersizedtoallowforexpansion
andcontraction).
3.Aligntheoutsideedgeoftheotherendrailwiththeoutsideedgeofthebottomrailofthefrontlid.
4.Alignthetoprailwiththeoutsideedgesofbothoftheendrails.
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5.Clampthefrontlidatthetopandbottomateachendrail.
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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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RecommendedStepstoSandandFinish
yourGerstner®KitChest.
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1.Flushupalljoinery.Thismaybedonewithaflushcutrouterbitorbyhandsanding.
2.Roundoveralledgesofthechestasdesired.Thecornerprotectorshavea3/16”radius.
3.Fitthedrawerstotheboxmakingsurethatthegapsbetweenthedrawersareuniform.Becauseallwoodswells
undercertainconditions,adrawerfitwithminimalclearanceisnotrecommended.(Gerstnerrecommends1/32”1/16"
gaponallsidesofthedrawer.)
4.Finalsandallpartsofyourchesttodesiredgrit.(Gerstnerrecommendsatleast150grit).InstalltheFrontLidStop
Strip(seenextpagefordetails).
5.Stainandfinishthepartsasdesired.Gerstnerstainsandthenapplies12coatsofalacquersealerandthen12top
coatsoflacquer.(Makesuretouseastylefinishthatyouarecomfortableworkingwith.)
6.Cutthefelttofittheboxanddrawers.
7.Usea50/50mixofanimalhideglueandwatertoinstallthefelt.Brushthemixtureontothewoodormetalsurface
andthencarefullypressthefeltintoplace.
8.Installhardwareonthechestasdesired.The4rubberbumpersaremountedonthebottomofthechest,usingthe4
1/2”screws.Thescrewgoesthroughtherubberbumperandthroughtheholeinthelegofthebottomcorner.
9.Installbothlidpinsinthefrontlid.Thepinsshouldprotrudeabout1/8”fromtheedgeofthefrontlid.The2felt
dotswillbeputinthebottomofthechest,3/4"fromthefrontedgetokeepthefrontlidfromrubbingagainstthe
bottomofthechest.
10.Thereisavideoonhowtoinstallyourfrontlidinyourchest.Thevideocanbeseenonourwebsiteat
www.GerstnerUSA.com.videos.htm.
10.Rubparaffinwaxontothedrawersandtheinsideofthechesttohelpthedrawersglidesmoothly.
11.Congratulations,youarefinished,nowsitbackandenjoyalifetimeofuseofyournewchest.
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Haveaquestion?
CallH.Gerstner&Sonsat9372281662
AskforScottCampbellorBertWilson.

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H.Gerstner&Sons20GerstnerWayDayton,Ohio45402www.GerstnerUSA.com9372281662
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FrontLidPins
 Oncethefrontlidhasbeenfittothechest,youwillneedtodrillfortheFrontLidPinswitha5/32"diameterdrill
bit.Thelocationsfortheholesareshownbelow.
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FrontLidStopStrip
1.Onceyouhavecompletedthesandingofthechestandthefrontlid,youwillneedtoinstallthefrontlidstop
strip.
2.Thefrontlidstopstripkeepsthefrontlidfrompushingtoofarinsidethechestatthetopwhenthefrontlidis
intheupright,lockedposition.Thestopstripismountedtotheundersideofthechesttop.Thedistancefromthefront
edgeisdeterminedbyhowmuchyousandedyourfrontlid.Measurethethicknessofyourfrontlid,andthengluethe
stopstripthesamedimensionbackfromthefrontedge.Makesurethenotchforthelockisfacingtowardthefrontof
thechest,andnotcoveringthelockslotbeforeyougluethestopstripintoplace.
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3.Onceyourgluethestripinplace,clampthestripuntilthegluedries.
4.Resumesandingandfinishingyourchest.