Box with fancy corners

[steven newman]

Woke me up from a sound sleep...first good night's sleep in quite a while, too but....Single Brain Cell Sketch Up had come up with an idea...and would not let it ( or ME) rest.

 

Idea is to take a few 1 x 4 x whatever Ash boards and make a Jewelry Box with beaded, mitered corners...hmmm...Cut the sides to about the right size.....add a groove to the end grain ends..

haven't cut anything, just yet......as for the miters?

Each end gets 2 miter cuts.  Figure I can tilt the tablesaw to 45 degrees, and run each end through to make both cuts..in theory

Because two ends will fit like this...

Not much space for glue?    Until I add a beaded spline....

Bead via the Stanley 45, then a few cuts so this thing will fit into the grooves...

I'd form up the bead first....then saw cuts to remove the waste....one cut to clean off from the bead...then a couple cuts to free the piece up...

 

May carry that mitered edge all the way around....may even do the lid to match,  maybe...bottom will get housed into a groove...like the bottom of a drawer. 

 

And, this is what woke me up?

 

Have things drawn up on paper, have to hope Boris doesn't steal the Plan...

 

Stay tuned...

[Gunny]

I have the beer and popcorn. 

[lew]

I like that idea!

[Fred W. Hargis Jr]

It will be interesting to see that come together.

[Cal]

Stevens October project.  Any wagers on when it will be completed?

[steven newman]

We'll see how things go.   Need to haul one plank to the shop, and...clean off the top of the tablesaw.....we have work for it to do

 

Need to decide on what size to make this thing....and work up a "cut-list"....maybe...have 6' of 1 x 6 Ash to work with....

 

Stay tuned....

[steven newman]

Spent 1/2 an hour IN the shop...knee is currently "on ice"....needed to clean the dump up a bit...6 weeks since anything has been done?

Any flat surface becomes a "catch-all"....need this mess cleared off..

Might need a dust-shovel..instead of a Dustpan?  Top of the bench wasn't much better...

Grinder was for tool rehab/sharpening...wound up taking the airhose to everything....then swept things up a bit.  LOTS of spiders to evict, too.

 

Tablesaw?

Looks a little better, now.   On a whim, decided to check the mitre gauge for square to the blade...

Was "off" a couple degrees...got that fixed up.   There was a load of clothes in the dryer....decided to try hauling it upstairs....one step at a time. 

 

I'll take the BIG dustpan to the shop ....after rehab tomorrow...and see about hauling that 1 x 6 x 6' Ash plank down there as well.   !/2 an hour seems to be the "Time Limit" at the moment...goal for tomorrow?   Cross cut a few parts....and get them ready to use....might just stay with the tablesaw....can't "push-off" with the right leg, at  the moment...

 

Stay tuned..

[lew]

Geeze, Stephen, take it a little easy!

[Gerald]

I was thinking that this would take 3 to 4 weeks but with the switch to tablesaw? I think he is getting the point to slow down so maybe 2 weeks.

[steven newman]

Well..Knee rehab this morning...and she had me working up a sweat...took a rest break when I got back home.    Had to haul a quilt to the washer, and get it started up...after Lunch?   Well, needed to sort out 3 planes, to get them ready to ship out.

.

Tracked down my tape measure, too...plank also arrived in the shop, after Lunch.   By then, the quilt was washed, and needed loaded into the dryer...

Plank is 1 x 6 by 6'4"....not much room left IN the shop...end closest to the camera?

Not really very good...maybe the other end is better?

I'll pass...measured from that black mark over about..19" or so...

Going to be just rough cuts...measure another 19" or so..make a second mark...tablesaw to make a couple cuts..

Red line is scrap....bad end #2...goal now was to rip to get one straight edge, then run that against the fence set at 4" from the blade..

Now, comes a problem....from these 2 blanks, I need 4 pieces...cut so the grain will go around the outside of the box..I hope..

Yep..."Follow that grain!"...problem being?    Sides are 12" long, ends are 6" long...have to keep track of the way the grain lined up in the plank is the way it lines up around the box....like I merely folded it around...in theory...a few marks to start out...square an end, measure out the required amount ( 6" or 12") and make another cut..winds up like this...

Reset the tablesaw....

Was hoping just 2 passes per end....well, I tried...

Missed it by that much, Chief.   Reset again...

I guess that will just have to do.   Next...tilt the saw blade to 45 degrees, adjust the Zero Clearance Overlay a tad...reset the fence a bit..

And try to cut a couple bevels...."Jig" wanted to waddle a bit (like me?) decided I needed a better jig..

And safer, too.  thin strip keep the wiggles away...extra c clamp keeps boards flat..and prevent it from tilt into the sawblade.  Test fit?

Plan says it should look like this...and..

Came pretty close.  these bevels were soon done...had a few more to cut...after an adjustment...

These are supposed to be the outside, "Show" faces...insides will get something different...details?

Will have to go back and sort out which corner goes where...later.   As for the splines?

These came from the 2 blanks for the sides....need to make a pattern to follow....using the existing corner joints....

 

Might be a day or 2, before I can fire up the Stanley 45 Bead Cutter.   Since these are plenty long, I can simply screw them down to the bench to hold them still.  

 

Next Rehab if Friday morning...we'll see what they say, then.

 

Stay tuned.   1-1/2 hours, before the knee said "Enough!" Brought the dried quilt back upstairs, and rested up the knee...and me...

[lew]

1 hour ago, steven newman said:

1-1/2 hours,

It would have taken me 2 days!

[Gunny]

2 hours ago, lew said:

It would have taken me 2 days!

 

I am thinking two weeks for myself to get that far.....  Maybe

[steven newman]

As for the grain matching stuff...

Doesn't look too far off?  This is a view of the insides of the 4 sides  As for them sticks sitting there?

 

First I need to joint an edge...

Then form half of a bead...

Had a low spot on this end...why it looks a bit "flat".....rotate and do the other half of the bead...

Then remove all the "waste" until the spline appears...

Waiting until the last cut to separate from the 1 x 6 slab..LOTS of saw cuts...trying to "whittle" it down a bit...this one took about 20 cuts..

So..NOW I have a pattern...  One in the background?   Meh...we'll see.  Once the splines are made, THEN I can set up to plough the groove for a bottom panel...and then a rebate around the top to set a lid into.   Thinking Ash is not the best wood for this sort of molding details...

Stay tuned....

[Gunny]

You're making this complicated to annoy me. I know it.

[steven newman]

1 hour later...other 2 splines are done...and the grooves for the bottom panel have been milled...am now resting up a sore knee...will take the camera back down after awhile..once the knee stops hurting...

[steven newman]

Roh...Kay, Raggy....Photos?

Corner getting fitted up with a spline..

All the splines are done....working on some grooves, next..

Needed a jig built, things wanted to move around a bit....

 

"Groovy, man.."   Had thought about using thin ash for the floor...

Until I found a couple 1/4" plywood panels stashed away....one for a floor, one for a tray?

 

Need to decide on a lid, next...and figure out what rebate I'll need for that...flat panel...or..a raised panel...hmmm?  ..May get a glue up started...whenever I figure out HOW to clamp this thing together.....

 

Stay tuned..

[steven newman]

Had Laundry Detail last night...Grandson hauled the very FULL hamper to the shop...where I could take over from there....WHEN I got around to it...

 

 

Decided to try to glue in the splines at least......Got to the point that clamps got involved.....one needed a "Hammer Assist" to fully seat into a groove....plywood panel for the bottom needed trimmed a bit...broke a bit of that one sticky spline.....game was now ON....Cussing enough that even R Lee Ermy would blush...let alone our Gunny....we are headed for a full glue up...

 

First off, the rebate around the top edges needed done....then fight the glue and clamps....and splines...and sides that seemed to want to just fall flat, trying to head for the floor like a big magnet was down there....  Too many parts, too many clamps...not even enough hands at once

 

Finally..a forest of clamps arrived.. 

You know something was up, when after attached the second set of clamps, you HAVE to  go back and tighten the first set,,,again..Spline is the one a piece flew off of, and I had to FIND that critter, clean it, and then glue it in place, too...

Hard to see a line?    As for the inside view of this...thing..

The Lid,when I get back to the shop...will fit into that rebate....what sticks up above the sides of the box will get a bevel....to make the lid a "raised" panel look.

 

Clamps can sit there a day..or 2....before they come off....then clean things up....splines are sticking up into the rebates..in the way...will trim those back a bit....Have that "Monday" thing tomorrow...so...no rush...

 

Stay tuned

 

[Gunny]

Looks like a anorexic forest of trees...........

[steven newman]

Sanded, planed, beveled....and more...lid was tried out...once the clamps had left..

Hmmm...maybe a coat of stain will help out...

Meh..still has a Caskety look to it.....this lid got tossed out...the rebates were bad, lid would not fit right...

In this shop, Mistakes will get turned into firewood....so...off with that lid....and the rebate was "leveled"

May give this a second try...to remove them grooves?   Meanwhile..

These 2 are too short...might work them into a tray....these are  cut-offs...as the 2 that ARE the right length were worked over a bit...

 

Beltsander and plane to flatten them out...one was a tad thicker than the other...tablesaw to remove the "excess"...edges were straightened, then both blanks were ripped to just over 3" wide....sawn edges were then jointed ( Millers Falls No.15 Jumbo Jack) for a gap free glue joint...and then the fun began...

 

Trying to remember what  "Forest of Clamps" sounds like in French....maybe that will sound better, classier?

 

To keep this flat, double cauls were used on the ends...

Have a BIG, old clamp that can reach into the center, with LARGE pads, to flatten the center, as well..

 

Let this sit a day, or two...then decide on how it will sit on the box. 

 

Stay tuned 

[lew]

I see what you mean about the "Caskety look"