Steps
STEP 1
Cut the base of the paper towel holder to size (9" x 3¼") from a piece of ½" thick board. Mark a rectangle 7½" x 1¾" on the cut board. With a 5/8" spade bit, drill holes at each corner of the rectangle to create the rounded corners.
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STEP 2
Cut the Opening Clamp the board to the work surface. Using a jigsaw, cut the line between the holes drilled in step one to complete the rectangular opening.
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STEP 3
Set up the saw to cut the crown molding. Tilt the bevel of the blade to 33.9-degrees, and then twist the miter angle of the blade to 31.6-degrees. (Note these adjustments are for crown molding with a 52-degree/38-degree molding.)
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STEP 4
Cut the First Piece of Crown Molding On the bottom edge, mark 3¼" from the end of the board. Orient the molding so that the miter creates a long point at the top edge of the molding and the bevel cuts back into the thickness of the molding.
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STEP 5
Finish Cutting the Crown Molding Finish cutting the molding so that the bottom edge of each piece fits against its corresponding edge of the base board cut in step one.
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STEP 6
Cut the Back Miter the ends of the ½-inch-thick back board to 38-degrees, or the spring angle of the crown molding.
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STEP 7
Assemble the Base and Back Apply wood glue to the edge of the base board. Center the back on the edge of the base, and then nail it into place using a pneumatic nail gun and 1-inch brad nails.
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STEP 8
Place the first piece of crown molding along the edge of the base so that it covers the edge of the back board. Apply glue to the edge of the base and the back boards. Nail through the crown and into the base and back boards to hold it in place.
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STEP 9
Apply wood glue to the edge of the installed crown molding piece, and along the front edge of the base board. Place the center piece of crown molding in place, concentrating on the joint with the installed crown. Nail to hold the piece in place.
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STEP 10
Attach the Last Side Glue and secure the remaining piece of crown molding. Add painter's tape across the joints to hold them tight while the glue dries.
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STEP 11
Cut and Place the Lid Cut a piece of ¼-inch board or scrap plywood to a size of 14¼-inches-long-by-6-inches wide. Place the board onto the assembly as a removable cap.
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