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FIG. D: Dispenser Details
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1. Set your saw to an angle and rip the lid (22-1/2 degrees) and mounting cleat (45 degrees). Clamp or screw the boards to your workbench and use a straight guide for these cuts. Cut the other parts to length (see cutting list and fig. D) using a speed square as a guide to keep the cuts square.
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2. Lay out the bays on the bin bottom using Fig. D as a guide. Find the center of each bay and draw the circular cutout for the blast gates with a compass. Drill a 5/8-in. starter hole and cut out the openings with a jigsaw.
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3. Mount the blast gates in the openings. Replace the bolts that hold the two sides of the blast gate together with four 1-in. No. 6 wood screws. Don’t overtighten or you’ll pinch the gate closed. (Note: We also drilled a 3/8-in. hole to recess a little nub and bolt in the top of our blast gate.)
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4. Glue and screw the two-piece sides together (Fig. D). Use 1-1/4 in. screws and predrill with a 1/8-in. bit to avoid splitting the wood.
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5. Predrill and screw the center divider to the bin bottom with 2-1/4 in. Trim head screws. Then add the sides, bottom, and top. Next attach the back and the top half of the cleat with 1-1/4 in. screws.
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6. Set acrylic in place, leaving 1/8-in. gap on all sides for expansion. Cut and fit the moldings (Fig. D). Nail the sides and bottom moldings to the bin with 3d finish nails, sandwiching the acrylic in place. Set the center molding and predrill 1/16-in. nail holes through both the molding and acrylic.
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7. Remove the center molding and enlarge the hole in the acrylic with a 1/4-in. bit to provide room for expansion. Press the drill gently so the bit doesn’t grab and crack the acrylic. Replace the molding and nail it on. Cut the piano hinge to length and screw it to the top.
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8. Level and screw the other half of the mounting cleat to the wall with four 2-1/2 in. screws driven into the wall studs. Hang the cabinet on the interlocking mounting cleats.
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