Builder's Studio: Tambour Console Cabinet

Cut the 2’ x 8’ ¾” walnut veneer plywood in half using a table saw. This will give us a rough 12” wide top and bottom. Measure and cut the plywood to a final length of 50”.

To round the ends of the top and bottom, use an adjustable compass to mark a half circle on each end of the plywood. Find the center of the board and place the anchor point of the compass in that location. Stretch the compass to the right edge of the board. Lock the width of the compass. Move the compass 90° and slide the tool back until the pencil lines up with the edge of the board. Make sure the anchor point is still centered. After the compass is set, mark out the line of your cut making sure each edge is aligned properly. Repeat the process for each end of the board. Cut using a jigsaw/bandsaw. Once the ends of the boards have been cut, take a finish sander to touch up the final shape.

Measure and cut the tambour panels to 27” using a miter saw/circular saw.

Next, create smaller mounting plates that will sit inside the tambour panels to help with assembly. Measure 1 ½” from the edge of the plywood. Subtract this distance from the distance the compass was set at previously. This creates a half circle that is 1 ½” smaller from each edge of the plywood. Cut mounting plates to a 9” width. Trace, mark, and cut the mounting plates. Create four mounting plates.

To support and align the tambour panels, add 1’ x 2’ lumber on each of the mounting plates. Notch out five locations on each of the mounting plates. Do this for all four mounting plates. Set the support boards aside.

To attach the mounting plates to the plywood, center the plates and ensure there is proper overhang. Secure with wood glue and a brad nailer.

Cut 1’ x 2’ support board lumber to length at 27”. This ensures the top sits flush against the tambour and support boards. Install the boards to the bottom of the cabinet with wood glue and a brad nailer.

Apply wood glue into the notches of the top board and install it into the support boards. Make sure the notches are aligned with the boards. You may need to use a mallet to ensure everything is assembled and secure. Make sure each end is the same height from the work surface before using a brad nailer.

We are now moving onto installing the Wheeler Classic Bun Foot. We are going to create mounting blocks to install these. Cut the 4” x 1” True Stock Lumber to a length of 4”. Find the center of the mounting block and pre-drill a ½” hole in the middle.

Install the threaded inserts into the mounting blocks. To watch a more detailed demonstration, see here.

We installed the mounting blocks on the very edge of the bottom to allow for maximum width between the furniture feet. The location of the mounting blocks and furniture feet is the builder's preference. Pre-drill 4 holes in each corner of the mounting blocks. Attach using a proper size wood screw.

Screw in the furniture feet into the threaded inserts using the pre-installed hanger bolts (optional service from Osborne).

Next, install two tambour panels on each end of the cabinet. Brush on wood glue to each support board. Align the end of the tambour panel to the center of the cabinet. Attach the tambour panels to the support boards using a brad nailer. Attach the second tambour panel.

Repeat the tambour panel application on the other side of your console.

Create two side panels for the interior of the cabinet. Cut the panels with the same height (27”) and width (9”) as the support board.

Add wood glue to the top and bottom of the cabinet. Slide the panel in place and attach using a brad nail through the tambour slats. Complete this for the other end of the cabinet.

Cut out ledges for the cabinet shelf using leftover 4” x 1” True Stock Lumber. The shelf ledge should be cut to width at 1” and length at 8”. Attach the supports horizontally in the middle of the cabinet using wood glue and a brad nailer.

Measure and cut the shelf to width at 9” and length at 28 ¼”.

Add Osborne’s Walnut Edge Banding to the edge of the walnut plywood. For a more detailed demonstration of this step, see here.

Sand the top of the cabinet to 220 grit and apply your desired finish.