Wood Box Project

September 10, 2022

Lets see..we have a plank of Maple..

Not only do we have a set of plans, we also have a "Prototype"..

Had to haul the plank to the shop...do a bit of lay out.. :WonderScratch:

I WAS going to use a full sized saw to make the cross cuts, but..

Choose this little "Panel saw" instead. 20" long, 10 ppi Disston D8 ( old style, the "8" is inside of the "D" in the etch)

Between the plan and the prototype...was able to lay out a few blanks...

As I need a bottom panel, a panel for the lid, a panel for the ends, and the front and back...which left this..

For some of the drawer parts. All of these were 7/8" thick...way too much...decided to resaw things down a bit, according to the Plan: Lid is 11/16" thick, bottom panel is 1/2" thick...the four sides were supposed to be 1/2" as well....will be 3/8" instead. Had one edge that needed jointed..

As it had a slight bevel going on. Need these blanks to stand up on edge, for the next step..

Because of the way the shop does resaws...I need to mill a kerf for the rip saw to follow. Saw is raised as high as it can go...fence is set for each thickness to be milled. In this case, it is set for 11/16" width..boards are shoved through on edge...

Then rotated until all 4 edges are done...

This is the 1/2" thick bottom panel...then it is time for the handsaw... :SaluteandRun:

1st try...kept wanting to flip out of the vise. :PullingHair: ..managed to finish this cut, from both ends.. :TwoThumbsUp:

Decided on a "better way" to hold the panel... :OldManSmiley:

Since the end vise will open just enough...results? :TwoThumbsUp:

I have to be careful, though...usual routine is to cut from each end, and meet somewhere in the center...hard to see where, so when I do reach the other cut..

The saw will drop down onto the benchtop. However, my left pinky is also right at the edge of the handle ( 2 handed grip) and yes, it did get hit..once. Just a matter of "follow that kerf".. :SaluteandRun:

Results? :ChinScratch:

Just have to smooth things out, tomorrow. :rolleyes: Have that Drawer parts blank to resaw, yet. Also tomorrow.

Had quite enough of a Cardio Workout for one day....even with the fan on high, was still soaked through...swept the shop, and headed for a cold Tonic & Gin.

Stay tuned.. :cowboy:

September 10, 2022

You’d think we could get trees to grow the exact sizes we need….

September 10, 2022

Haven't you heard of the rectangular trees that grow on geometry island? Of course once you pick one out that has a cross section to match your desired part a slice through those trees is always and end grain board. Great for butcherblocks though! A diagonal cut through the trunk you can get a rectangle, although you'll need to trim the ends square.

Related to this thread I really appreciate the sequential photo process sequence. I'm a little wary about the use of plans though.

Edited September 10, 2022 by 4DThinker

September 10, 2022

Wood Box Project for September

September 10, 2022

Another day, another 90 minutes in the.. :SaluteandRun:

Made by a friend of mine. :Praise:

Had one last resaw to do.. :ChinScratch:

Results? :WonderScratch:

Needed for the drawer back and the drawer sides... :OldManSmiley:

After a bit of saw work...to remove the bad section...that BIG knot had to go. :MachineGun:

Once the four sides were ripped for width.. :ChinScratch:

And the 2 ends were cut for length....was time to plane things flat...

Working on the front of the box..back was also done...as was the 2 ends... :OldManSmiley:

Edges did need a bit of work, though.. :ChinScratch:

Yeah...we have ways..

Look a little bit better? Same with the ends... :ChinScratch:

Once I figured out which will be the front, there was one last rip cut to do.. :SaluteandRun:

The one with the "B" will be the front of the drawer...like this... :OldManSmiley:

I also had to flatten the lid and the box's bottom panel.... :Cheer:

Then just sweep things up....back of the lower legs were starting to cramp a bit...90 minutes of shoptime, and I was soaked, even with the fan blowing on me. Should be about ready to start some joinery tomorrow? :ChinScratch:

Stay tuned.. :cowboy:

September 13, 2022

Sunday was an attempt at lay outs.. :WonderScratch:

Trying to lay out for a groove, to house the compartment's floor board

Trying to get the grain to line up, too.. :ChinScratch:

I saved the 1/4" thick "off-cut" from the resaws...to use as a floor board. There needs to be a rebate to house it in the front of the box..

Then set up a combo square to carry those lines along the side and back panels...

Making sure to measure from the top edge of each part. :OldManSmiley: Then the dovetails can be laid out...tools, too :SaluteandRun:

Then, a saw was brought out..

We'll see how this $2 Jackson saw works... :Cheer:

Then knife a line a few times..

And chop out the waste..

needed a bit of clean up... :ChinScratch:

Nice..but..backwards.. :BangingHead: .oh well...we can fix that...before I lay out the tails. Then just trace around the pins, with the groove now re-located to the other face.. :ChinScratch:

Bandsaw to make these cuts..then chop out the waste, enough to try a dry fit...or 3... :rolleyes:

1st corners are always sloppy. :ArguingSmileys: ..at least this will be a back corner....was on Laundry Detail, too.. :DevilLaughing:

Which meant I needed to be done with the woodworking, when the clothes went into the dryer... :SaluteandRun:

Then sweep up a bit..90 minutes of shoptime...and I was getting a bit soaked (had to change me shirt! :JawDrop: ) so, that was it for Sunday...

Monday, the shop was closed...will see how Tuesday goes along..

Stay tuned.. :cowboy:

September 14, 2022

Tuesday in the shop....had worse issues than a backwards part.....Camera! :ArguingSmileys: Went to take the 1st photo of the day....was promptly informed that the "Memory Card" was full...sat the dang thing aside...and continue on.. :SaluteandRun: ..2 hours of shop time! Without having to stop to take a photo? :JawDrop:

Tasks completed? Corners #2 and #3 were done. Grooves in the 2 ends, and the back were milled, plane reset, rebate milled. Floor board for the compartment was trimmed to size. :Praise: Then back upstairs...to unload a memory card.....made a copy of that, and moved it to a safe place....then hit "SHRED" to empty the card.. :MachineGun: ....then back to the shop..and take a few "After" photos..soooo.. :Tapping:

Plan right now, is to fill them small square openings with a plug of Rosewood. This is sitting on it's top.. :TwoThumbsUp:

That is a 3/16" thick Maple panel...from one of the resaws...

To get it short enough, Mitre Box to get close, use the WR#62 to peel away at each end until things fit....Didn't care for the LOUD screeeech it made cutting end grain. :PullingHair: Width was trimmed about 1"....first with the bandsaw,leaving the line...then back to the #62, until the panel was a slip fit... :ChinScratch:

To make 3 of these? :ChinScratch:

Grooves...the Stanley 45 was set up, with a 3/16" wide cutter.. :OldManSmiley:

That shiny thingy on the back rod? Is called a cam rest...adds support, when the groove is out in the middle of a board. To do a rebate?

Slide the fence all the way in, until it is touching the side of the cutter. Depth stop was set to 3/16" deep.

Maybe later today.. :WonderScratch:

I can get the last corner done, and a glue up? We'll see :ChinScratch:

Stay tuned.. :cowboy:

September 14, 2022

Well I have looked at that shiny piece on my Stanley and wondered what it was. Thanks

September 14, 2022

Ooh, Did someone mention seeing a shiny thing? Never mind, there goes a squirrel. :lol: Wait, what were we talking about?

September 15, 2022

Corner #4...was a bear to put together. took three tries to get one layout right... :ArguingSmileys:

First 2 tries..pins weren't in the right direction...finally got this sawn..

Then chopped out....then traced around the lay out these..

I use a bandsaw for these cuts, as I can SEE where I am cutting, and able to follow a line better..

Dry fits...were giving me "fits" :ArguingSmileys: seems two grooves weren't quite lined up...more chisel and plane work :BangingHead:

Finally, was ready for the big fight....and...

let the glue flow! Why is it, that glue always dries fast on fingers, but not in wood? :WonderScratch:

Yep, floor board was also glued into place ( no squeaks?) :TwoThumbsUp:

Let this sit a day, or two ( Honey-do List, on a Friday? :BugEyeSmiley: ) Then clean this mess up, and work on the base and lid...then see about building a drawer?

Stay tuned.. :cowboy:

September 15, 2022

Ok...clamps were removed, for a while, at least...Spent part of today's shop time...cleaning the box up...squaring corners.. :Cheer:

While keeping the sides straight...

Getting close... :Tapping:

Enough that I could center the box up on the base... :TwoThumbsUp:

base needed to match the Prototype, though.. :ChinScratch:

And..no..you can't do that with a router bit...Paul Sellers did use one of these "Molding" planes.. :JawDrop:

Yep...After I had traced around the centered box...over to the bench vise we go.. :SaluteandRun:

Work on the end grain first...rounding down from a center line, to the traced out line....sand paper to smooth this out...rotate.. :Cheer:

And repeat...then do the other end grain. Because when you then do the long grain sides... :ChinScratch:

You wind up with a "crisp corner" as Sellers calls it. :TwoThumbsUp: A bit of sanding to smooth out things...set the box back on the base...make sure it is still centered..make a mark at each corner...because, just like Sellers did... :ChinScratch:

Glue, brush, and a few good clamps, keeping an eye out on the marks...the lip in the front is the same as the lip around in back.. :OldManSmiley:

Letting this sit a day....will need the clamps taken off before the next task can be done...the lid. Then we'll see about building a drawer?

Busy day? :DevilLaughing:

Ehhhh, could be? :WonderScratch:

Stay tuned.. :cowboy:

September 18, 2022

Friday's tasks :Cheer:

Involved this tool, among others.. :JawDrop:

Including that smoother plane....coping saw was to clean up dovetails...

hand plane to do the round-overs, again.. :ChinScratch:

Once all 4 edges were done, time for hinges.. :OldManSmiley:

And installed on the box.. :TwoThumbsUp:

Close the lid, before a spider gets in there! :MachineGun:

Which leaves a drawer to build... :SaluteandRun:

Parts get cut for length... :TwoThumbsUp:

Checked for height. Drawer front covers up a false front, and the plywood bottom... :OldManSmiley:

Drawer box and bottom. Corners of the box are dovetailed , plywood to help keep the box square.. :ChinScratch: .

Once the glue had dried, then the Front could be glued on? Once the box had been cleaned up, of course, and check to see how it fits...THEN the front was attached.. :Cheer: