Hand Tool Journey #32: Stanley SW #246 Miter Box Restoration #6..Metal Fabbin it Up in Here..

  • Advertise with us
Blog entry by Airframer posted 04-29-2014 11:31 PM 2698 reads 0 times favorited 8 comments Add to Favorites Watch
« Part 31: Stanley SW #246 Miter Box Restoration #5.. All Cleaned Up Just Waiting On Missing Parts.. Part 32 of Hand Tool Journey series Part 33: Stanley SW #246 Miter Box Restoration #6.. Well Frack.. »

So yesterday we left off with a clean and reassembled mitre box with a few missing accompaniments. I was also left with a broken drill press (piss.. damn you HF!!!!!!)..

Anyhoo.. the drill press saga will come into play in a bit but first I needed to draw up some plans for the missing tree from a photo provided by a fellow LJ.

I blew it up on my computer screen till it was scale to my ruler and started mapping it out on some graph paper ending up with this..

Now…. I hear a lot of folks on here talk about working with metal as if it is a foreign subject but really it is not much different than working with wood and in some respects it’s a bit easier. No grain direction to contend with, no seasonal movement to consider and nearly anything can be fixed with some filing lol. If you own old tools you should own a few metal working tools imho.. but anyhoo.. where were we.. oh yes..

Just like if I was to cut this out of a chunk of wood I attach the plan to the aluminum block with spray adhesive.

Now I cut off the excess on the side (gonna hang onto it and use it for the flat base portion)

I put a course toothed blade on my hack saw and cut just outside the line.. NEVER CUT THE LINE!!. You want to cut just outside it and file to the line. This goes just like cutting a dovetail. Start the cut and watch the line. It will seem like you are getting nowhere at first but in no time your done!

Then I file to the line. For those who don’t know, files cut in one direction only. Don’t use it like a saw.. push lift reset push. If it starts squeaking that means it’s filled with shavings and needs a quick cleaning.

Now here is where I wish I had my drill press. I need to drill 2 5/16” holes for the rods to pass through. Would be an easy task with a drill press but.. I must have left my easy button at work or something.

I decided on a dowel jig and my corded drill for this task.

When drilling in metal faster gets you nowhere.. slow and even pressure will actually drill faster.. keep that in mind.

I drilled both holes.. Not bad..

Then flipped it over and.. well piss.. Again DAMN YOU HF!!!!

Oh well.. that one will have to be filled and redrilled when I get to braising this together. Live and learn right?

At least they line up with the base..

Next I laid out my cut lines and started cutting the rest of the rough shape out.

And this is what I have ended with for today…

Next will be hogging out the rest of the waste with some carbide cutters in my dremel, fixing a hole (darnnit) and working on the base. Hang in there.. playing with fire is coming up soon!

-- Eric - "I'm getting proficient with these hand jobbers. - BigRedKnothead"

8 comments so far

View AnthonyReed's profile


9716 posts in 2440 days

#1 posted 04-29-2014 11:54 PM

Fun stuff AF. Thanks.

-- ~Tony

View Smitty_Cabinetshop's profile


15353 posts in 2618 days

#2 posted 04-30-2014 12:13 AM

Mucho worko. Wow, inspiring!

-- Don't anthropomorphize your handplanes. They hate it when you do that. -- OldTools Archive --

View Don Broussard's profile

Don Broussard

3550 posts in 2251 days

#3 posted 04-30-2014 12:22 AM

I must have left my easy button at work or something—that’s funny right there. Good stuff, AF. Looking forward to seeing your vintage miter box back in service.

-- People say I hammer like lightning. It's not that I'm fast -- it's that I never hit the same place twice!

View Don W's profile

Don W

18715 posts in 2567 days

#4 posted 04-30-2014 12:35 AM

Now that’s definitely not woodworking!

-- - Collecting is an investment in the past, and the future.

View Airframer's profile


3043 posts in 1953 days

#5 posted 04-30-2014 01:24 AM

I’m glad you guys enjoyed it. Next segment will be fun (I hope) as I get out the aluminum brazing rods and go to town with them. I’m trying to show how simple it is to work with metal because we all know… some parts just don’t exist anymore so whatcha gonna do lol.

-- Eric - "I'm getting proficient with these hand jobbers. - BigRedKnothead"

View johnstoneb's profile


2915 posts in 2172 days

#6 posted 04-30-2014 01:43 AM

A little something I learned many years ago when working with metal. drilling sawing ets especially drilling.
soft metals aluminum, copper. High speed, slow feed
Hard metals steel, cast low speed, high feed.

It works.

-- Bruce, Boise, ID

View ToddJB's profile


7947 posts in 2130 days

#7 posted 04-30-2014 03:11 PM

AF, I agree that if you’re going to play with old tools basic metal working is important. This is an ambitious piece to make… lots of work. Good on you.

The piece in the example has an extended base, but yours does not, is that by design?

-- I came - I sawed - I over-built

View Airframer's profile


3043 posts in 1953 days

#8 posted 04-30-2014 03:12 PM

That is being added when I attach the base to it. All in due time.

-- Eric - "I'm getting proficient with these hand jobbers. - BigRedKnothead"

Have your say...

You must be signed in to post the comments.

DISCLAIMER: Any posts on LJ are posted by individuals acting in their own right and do not necessarily reflect the views of LJ. LJ will not be held liable for the actions of any user.

Latest Projects | Latest Blog Entries | Latest Forum Topics