How to Make Replacement Drawers for a Roll Top Desk

An antique roll top desk can be a monetary investment that improves with age. However, some desks need repair to bring them back to optimal quality. The drawers in the pigeonhole in the interior of the tambour area may be broken or missing and replacement is necessary to give the desk new life. Matching the drawer's brass, wood stain and size is essential and may be difficult depending upon the age and style of the desk.

2- by 2-foot birch plywood, 1/2-inch thick
1- by 1-foot birch plywood, 1/2-inch thick
Screwdriver
Tape measure
Table saw
Wood stain
Sponge
Pencil
Dovetail jig
Router
Sandpaper
Rubber mallet
6- by 6-inch board of desk matching wood
Wood glue

Instructions

- 1
  Remove the brass drawer handle from the broken drawer by removing the screws with a screwdriver. If the drawer is missing, purchase a new handle that matches the style of the desk. If one is not available, you may need to replace all the brass on the desk for uniformity.
- 2
  Measure the open drawer space for height, width and length.
- 3
  Cut a 2- by 2-foot birch plywood board, half-inch thick, into two boards to the length measurement and two boards to the width measurement found eariler. For example, a small drawer will need two 3- by 12-inch boards and two 3- by 3-inch boards.
- 4
  Cut a one-eighth-inch dado into each board along the longer edge of the board using the table saw. Make the dado one-eighth-inch from the edge. If the board is 3 by 12 inches, make the dado into the 12-inch edge.
- 5
  Stain all four pieces of plywood with the chosen wood stain using a sponge. Allow the stain to dry for at least an hour.
- 6
  Mark an "L" on one lengthwise end of each board and an "R" on the other end with a pencil. These markings will determine which dovetail cut is placed on which end of the board.
- 7
  Attach the first dovetail jig, or pin pattern, to the table and cut all the ends of the boards marked with an "L" with a router. Replace the dovetail jig with the second, or tail, pattern and cut all the ends marked with an "R" using the router.
- 8
  Sand the dovetail joints to remove any chips but do not sand to the point where the cuts are altered.
- 9
  Connect the two longer boards to one of the shorter boards by aligning the dovetail joints and pounding the two pieces together with a rubber mallet. Take care to keep the dadoes together. Slide a one-eighth-inch thick plywood, cut to the same dimensions as the drawer, into the dadoes. Attach the fourth side of the drawer to the open end of the two longer sides.
- 10
  Attach the drawer facing with wood glue and tack nails. Hammer the tacks from the inside of the drawer to hide the tacks.
- 11
  Screw the brass drawer handle to the new drawer with a screwdriver.

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