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203K views 206 replies 92 participants last post by  JimInNM 
#1 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
 

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#2 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
Nice
 

Attachments

#3 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
Hey Al,

That's a Great, dedicated, assembly area. Are your clamps on a wall rack or Mobile rack?

Work Safely and have Fun. - Len
 

Attachments

#4 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
Nice setup. Everything right at hand
 

Attachments

#5 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
One thing that see Big Al that you could use is wax paper by laying it down under your glue up's the glue no longer sticks to the table and the wax paper peels right off the box, it doesn't stick to anything.
 

Attachments

#6 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
Blackie, good idea as always. You're probably right…wax paper would help, and I use it sometimes. What I usually do is just scrape the laminent with a wide, sharp putty knife and occasionally wash it down. I use foil on internal glue up inside boxes.
 

Attachments

#7 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
Wow, great ideas box guy. Im glad Im reading your blogs before I re-arrange my shop.
 

Attachments

#8 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
I like it,,, Good read not sure how I missed this series. Well on to part 2 Thx
 

Attachments

#9 ·
The Glue Up Table

The Glue Up Table

Table Wood Wood stain Machine tool Gas


In my shop the most important element in efficiency is organization. That means having what I need at hand when I need it. In the case of the glue up table it starts with a straight line that I can put the sides of the box against to line them up for glue-up.
Wood Automotive tire Audio equipment Motor vehicle Gas


This is a shop made holder for the tape dispenser. It allows me to have the tape already positioned over my work and it is easily removed from the holder.
Wood Shelving Paint Shelf Gas


Glue and brushes are essential. I keep my brushes in water and they don't clog up. I can use the same brush for months on end as long as I put it back in the water cup at the end of each use. Since I use the thicker Tightbond Trim and Molding glue it is essential to hold the bottle up-side down.

Wood Gas Machine Engineering Tool


Paper towels are another must. I use them to clean up and dry off the brushes when I first take them out of the water. They are handy here on the left.

Plant Terrestrial plant Wood Creative arts Art


My home made band clamps hang on a hook on the left. I can quickly reach them and put them back when I'm finished.

Circuit component Electrical wiring Audio equipment Electronic engineering Electronic component


An air hose is useful for blowing away dust before finish is applied and for the pin nailer I use to hold parts in place until the glue dries. The small shelf also holds a scraper for cleaning dried glue off the table and a screwdriver for cleaning away glue squirt out. I set the timer (silver left) for an hour to let me know when the glue has set up enough for me to work on the next step.

Table Wood Wood stain Machine tool Gas


Of course you need a nice bright task light and if you are wondering about the piece with the bars welded across it that is a press for attaching tops. The other boards are culls for the press.

In later chapters I will show the actual process of gluing a box together and talk about the press.
I saw your assembly\glue up table some months ago when you commented on my glue up box.

So, I thought I would build a glue up\assembly table.

Here is my version. Thought I would share.

Wood Flooring Hardwood Varnish Engineering
 

Attachments

#10 ·
Spline Making Jig

The Spline Cutting Jig

Wood Rectangle Wood stain Hardwood Flooring


I use this jig to make all my splines. Basically it is set up to use the band saw to cut triangles out of a long thin strip of wood. It is just a board with a runner for the guide slot and another board fastened at a 45 degree angle. Cutting small pieces on a table or radial saw is a disaster. Your fingers wind up in wrong places and the small pieces fly all over the shop (not good). This is a job for the band saw! If it is done well the splines will look like this…

Furniture Drawer Wood Chest of drawers Rectangle


A quick word about fit: Once you have cut a strip of wood to approximate size let's say 1/4 inch thick by 1 inch wide by 18 inches long, you fine-tune the fit with the planer so that this strip will easily, but barely slip back and forth in the spline slots you have cut in the box. If you make this fit too tight you will have to fight the work and pound the splines into place in the slot. A slip fit lets the splines and wood swell a little with the glue. A thin bit of glue will not show, but a spline that doesn't bottom out in the slot looks really bad when the box is finished.

Wood Wood stain Hardwood Varnish Flooring


Since splines are often made from expensive and rare woods, I try not to waste any of it. Why make a square spline for a triangular slot? So as you see in the picture you use the jig to cut a 45 across the strip and then FLIP IT OVER and make your next cut forming a triangle. The width of your strip really determines the size of the triangular spline. If you need a smaller spline, make your strip more narrow. Don't try to cut smaller 45s it just doesn't work. I usually push the strip a little beyond the blade before making the second cut so I get a flat spot at the point of the triangle. I use the flattened point to push the splines in place. It is easier on my fingers.

Wood Wood stain Hardwood Gas Plywood


Any scrap will do when you are experimenting with a jig, but when I have perfected a jig I try to make a pretty one. It makes time in the shop more fun, and I can take pride in using it. This one is made from a scrap of bird's eye maple and eucalyptus veneer.

This jig works better if it is thicker and allows the triangles to fall when cut and then be pushed slightly out of the way by the jig after you have cut through the strip. Don't push too hard as you cut, let the blade do the work. Pushing makes the triangles fly and you want to keep the triangles on the table of the bandsaw. The rough edges of the bandsaw cuts don't matter. You will just trim off the excess sticking out beyond the box edges with the bandsaw or sander anyhow. I use the hole in the end to hang the jig on the saw between uses.

Later I'll show more about splines. Have fun, and keep boxing.
 

Attachments

#11 ·
Spline Making Jig

The Spline Cutting Jig

Wood Rectangle Wood stain Hardwood Flooring


I use this jig to make all my splines. Basically it is set up to use the band saw to cut triangles out of a long thin strip of wood. It is just a board with a runner for the guide slot and another board fastened at a 45 degree angle. Cutting small pieces on a table or radial saw is a disaster. Your fingers wind up in wrong places and the small pieces fly all over the shop (not good). This is a job for the band saw! If it is done well the splines will look like this…

Furniture Drawer Wood Chest of drawers Rectangle


A quick word about fit: Once you have cut a strip of wood to approximate size let's say 1/4 inch thick by 1 inch wide by 18 inches long, you fine-tune the fit with the planer so that this strip will easily, but barely slip back and forth in the spline slots you have cut in the box. If you make this fit too tight you will have to fight the work and pound the splines into place in the slot. A slip fit lets the splines and wood swell a little with the glue. A thin bit of glue will not show, but a spline that doesn't bottom out in the slot looks really bad when the box is finished.

Wood Wood stain Hardwood Varnish Flooring


Since splines are often made from expensive and rare woods, I try not to waste any of it. Why make a square spline for a triangular slot? So as you see in the picture you use the jig to cut a 45 across the strip and then FLIP IT OVER and make your next cut forming a triangle. The width of your strip really determines the size of the triangular spline. If you need a smaller spline, make your strip more narrow. Don't try to cut smaller 45s it just doesn't work. I usually push the strip a little beyond the blade before making the second cut so I get a flat spot at the point of the triangle. I use the flattened point to push the splines in place. It is easier on my fingers.

Wood Wood stain Hardwood Gas Plywood


Any scrap will do when you are experimenting with a jig, but when I have perfected a jig I try to make a pretty one. It makes time in the shop more fun, and I can take pride in using it. This one is made from a scrap of bird's eye maple and eucalyptus veneer.

This jig works better if it is thicker and allows the triangles to fall when cut and then be pushed slightly out of the way by the jig after you have cut through the strip. Don't push too hard as you cut, let the blade do the work. Pushing makes the triangles fly and you want to keep the triangles on the table of the bandsaw. The rough edges of the bandsaw cuts don't matter. You will just trim off the excess sticking out beyond the box edges with the bandsaw or sander anyhow. I use the hole in the end to hang the jig on the saw between uses.

Later I'll show more about splines. Have fun, and keep boxing.
this is a BUENO JIG

and very nice looking too
 

Attachments

#25 ·
Cutting Spline Slots

Boxguy's Spline Slot Cutting Jig

Furniture Wood Rectangle Varnish Wood stain


Want to add corner splines like this?
,
,
Wood Hardwood Wood stain Gas Flooring


You need a jig like this!
.
.
This hard working (and dusty) jig is used on almost every box I make, and is quick and simple to build. It has a wide plywood board for a base, a long "trough" supported by 45 degree triangles cut from a 2X6 and a handle so you can pull it back to you. (I just made the handle out of a forking branch.) The long trough lets me use this for boxes that are large or small. The wide base lets me run the jig along the saw fence. Sliding the fence over so it is snug along the jig removes all the play in the slide and makes the jig extremely accurate.

Wood Wood stain Hardwood Gas Tool


If you spread the two sides of your "trough" apart a little, your box will touch both sides, but rests on the bottom. Touching the box to the bottom board is important because it lets you set the height of your saw cut accurately using the base of the jig as a starting point for your cut. I can now set the slot depth using those long square brass spacer bars to raise my blade to the proper height by just sliding the jig forward and setting the bars on top of the jig base. (Hint: when you are making the jig. Affix the back side of the trough so it aligns with the back end of the jig, then just set a box into the trough to align and set up the front side so the box touches the jig base and then fasten the front trough board in place.) There are two important things to notice in the above picture. First, I have drawn a pencil line on the jig that aligns with and is as wide as the dado blade. Second, there is a strip of 2 inch masking tape running across the back side of the trough. More about these next…

Wood Wood stain Hardwood Flooring Folk instrument


You can see the tape and the line on the outside top of the trough here. (The mark on the trough takes little looking, sorry.) Though I have posed this with a finished box, you can get the idea.

First, I mark where I want each spline cut to be made on the box blank itself with a pencil. (In this case I would have marked three 1/4 inch wide lines for the three splines.) Second, I align these penciled-in marks for the splines with the pencil marks on the trough that indicate where the blade will cut. Third, using the box itself as a ruler, I draw a line along the top of the box and across the masking tape. This pencil line across the tape will now become my indicator for locating the box on the jig for each cut.

I draw one line across the tape for each row of splines (in this case three marks) and put a number next to each line. (If you don't number the lines, I find it is too easy to lose track of where you are in the sequence and accidentally cut the same slot twice.)

To cut the slots I hold the box blank firmly in place with both hands, and use my body to shove the jig forward and over the dado blade. Do not bring the box blank backwards through the blade. Instead, after cutting the slot, lift or tilt the box blank up and above the blade then pull the jig back into place for the next cut. Making more than one pass through the dado blade will widen the slot slightly and you will not get a nice, tight fit on your finished spline. I cut all three slots in one corner then roll the box to the next corner and cut three more slots.

Table Wood Wood stain Gas Hardwood


I like to use the back of the trough as a foot so I can stand this large jig out of the way on the floor next to the saw. That is why I cut the hole-handle in the base board.

Wood Tire Wood stain Hardwood Gas


This shot shows the back of the jig. Notice the maple stop at the top so you don't push the jig too far forward with your body as you make the pass over the blade. It also shows the runner that fits in the saw's miter slot.
.
.
Wood Rectangle Chest Wood stain Hardwood

.
This jig and careful work will let you produce corner splines in your boxes that fit like a glove.

For instructions about making the splines themselves click here.

Conclusion:

It took me far longer to tell how to cut slots than it takes me to actually cut the slots in my boxes. With practice, blade height set up, locating the slots on the box blank, marking the lines on the masking tape, and actually cutting the slots with the dado blade only takes 5 to 10 minutes.

If you have questions or comments, just ask. Thanks for reading.
 

Attachments

#26 ·
Cutting Spline Slots

Boxguy's Spline Slot Cutting Jig

Furniture Wood Rectangle Varnish Wood stain


Want to add corner splines like this?
,
,
Wood Hardwood Wood stain Gas Flooring


You need a jig like this!
.
.
This hard working (and dusty) jig is used on almost every box I make, and is quick and simple to build. It has a wide plywood board for a base, a long "trough" supported by 45 degree triangles cut from a 2X6 and a handle so you can pull it back to you. (I just made the handle out of a forking branch.) The long trough lets me use this for boxes that are large or small. The wide base lets me run the jig along the saw fence. Sliding the fence over so it is snug along the jig removes all the play in the slide and makes the jig extremely accurate.

Wood Wood stain Hardwood Gas Tool


If you spread the two sides of your "trough" apart a little, your box will touch both sides, but rests on the bottom. Touching the box to the bottom board is important because it lets you set the height of your saw cut accurately using the base of the jig as a starting point for your cut. I can now set the slot depth using those long square brass spacer bars to raise my blade to the proper height by just sliding the jig forward and setting the bars on top of the jig base. (Hint: when you are making the jig. Affix the back side of the trough so it aligns with the back end of the jig, then just set a box into the trough to align and set up the front side so the box touches the jig base and then fasten the front trough board in place.) There are two important things to notice in the above picture. First, I have drawn a pencil line on the jig that aligns with and is as wide as the dado blade. Second, there is a strip of 2 inch masking tape running across the back side of the trough. More about these next…

Wood Wood stain Hardwood Flooring Folk instrument


You can see the tape and the line on the outside top of the trough here. (The mark on the trough takes little looking, sorry.) Though I have posed this with a finished box, you can get the idea.

First, I mark where I want each spline cut to be made on the box blank itself with a pencil. (In this case I would have marked three 1/4 inch wide lines for the three splines.) Second, I align these penciled-in marks for the splines with the pencil marks on the trough that indicate where the blade will cut. Third, using the box itself as a ruler, I draw a line along the top of the box and across the masking tape. This pencil line across the tape will now become my indicator for locating the box on the jig for each cut.

I draw one line across the tape for each row of splines (in this case three marks) and put a number next to each line. (If you don't number the lines, I find it is too easy to lose track of where you are in the sequence and accidentally cut the same slot twice.)

To cut the slots I hold the box blank firmly in place with both hands, and use my body to shove the jig forward and over the dado blade. Do not bring the box blank backwards through the blade. Instead, after cutting the slot, lift or tilt the box blank up and above the blade then pull the jig back into place for the next cut. Making more than one pass through the dado blade will widen the slot slightly and you will not get a nice, tight fit on your finished spline. I cut all three slots in one corner then roll the box to the next corner and cut three more slots.

Table Wood Wood stain Gas Hardwood


I like to use the back of the trough as a foot so I can stand this large jig out of the way on the floor next to the saw. That is why I cut the hole-handle in the base board.

Wood Tire Wood stain Hardwood Gas


This shot shows the back of the jig. Notice the maple stop at the top so you don't push the jig too far forward with your body as you make the pass over the blade. It also shows the runner that fits in the saw's miter slot.
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Wood Rectangle Chest Wood stain Hardwood

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This jig and careful work will let you produce corner splines in your boxes that fit like a glove.

For instructions about making the splines themselves click here.

Conclusion:

It took me far longer to tell how to cut slots than it takes me to actually cut the slots in my boxes. With practice, blade height set up, locating the slots on the box blank, marking the lines on the masking tape, and actually cutting the slots with the dado blade only takes 5 to 10 minutes.

If you have questions or comments, just ask. Thanks for reading.
VERY, VERY nice and simple jig. Clear and detailed. Thank you.

Is the miter slot and fence redundant? Can I just use fence? Is miter slot bar loose? and therefore you need fence.
 

Attachments

#43 ·
Separating The Top and Cutting a Hinge to Fit

How do you make a hinge and fit it in a box so that it looks like this when you are done?

Rectangle Wood Box Bag Cosmetics


You Could Use This!...My Hinge Station or a Hack Saw

Wood Workbench Engineering Machine tool Machine

.
.

Just Browsing? If you want to casually breeze through this just read the dark print and look at the pictures. For more serious readers, I have included details in the fine print.

Economics: Price is a major consideration if you are making boxes for sale. I simply can't afford to put $35 or more into a set of fine brass hinges and make any money on the boxes I sell. I wish I could. So I choose to use piano hinges that have been cut from a 4 foot length so they fit the particular box that I am working on at the moment. I use 1 1/16 inch wide brass coated steel hinges and try to keep my side thicknesses at 5/8 of an inch. Steel plated piano hinges are my compromise between economy. appearance, and function.

Reasoning: Other than money why this choice? I am trying to make boxes that will still be in use 100 years from now. With modern glues and careful joinery, I may have a chance. Piano hinges are the most stable and strongest way I know to join the lid to the bottom of a box and allow it to swing open. Other styles of boxes lend themselves well to pin hinges and pivot hinges on the outside of the box, but I have not made many of that style of box.

The Process In Pictures: It may take some scrolling, but I have tried to have a picture for each step.
.
.
.

Separating The Top:

Brown Wood Gas Tints and shades Wood stain


Set Your Blade Height: First use a scrap from the original board you started with to set your saw blade to slightly beyond the thickness of the side of your box. (If you lost the scrap you can set the blade by the edge showing on top or bottom, but it is more difficult to be accurate, especially if you rounded those edges as I have here.) Note the shop-made zero clearance insert…good idea.

Packing materials Wood Package delivery Hardwood Carton


Set Your Fence: Now set your fence to the proper position to cut your lid off. Always keep the lid to the left of your blade. Cut through the two long sides, but lower your blade so you don't quite cut through with the end cuts. Notice that I marked the back in chalk so I can be sure to put it back together properly after it is separated. With close grain patterns you often can't tell the front from the back until you apply a finish. Remember! For the two end cuts lower the blade enough so it doesn't cut all the way through the box side. This lowering keeps the blade from being pinched by the box. When the box pinches the saw blade a lot of bad things happen to the box and maybe to you as well.

Wood Gesture Wood stain Varnish Hardwood


Finish Cutting the Ends: Now cut the remaining sliver away in the two end cuts with a box cutter and separate the lid from the bottom.

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.
.

Making The Hinge:
.
.

Hand Wood Finger Wood stain Hardwood


Size It: The first step is to set your hinge on the box and determine how long it should be. Obviously you don't want it to end in the middle of a screw hole, but you do want it to be close to the inside edge of the box.

Hand Wood Finger Tool Wood stain


Cut The Hinge: I took an old metal-cutting band saw and made it into a tool specifically for this job, but you can cut it by hand using a hack saw.

Hand Wood Finger Gas Musical instrument accessory


Smoothing And Rounding: I use a cheap ($35) one inch belt sander that I bought from Grizzly for this. But you can use any sander or even just do it by hand. Just remove the burrs and any saw marks. I round off the inside and outside corners so they won't be too sharp and cut customers.

Hand Wood Finger Gas Stonemason's hammer


Shorten The Pin: Over time the hinge's pin would work loose and stick out as a sharp point. To prevent this I use a small punch to make the pin slide to one end. Shown here is a specialized tool. It is a magnet over a metal bar with a hole in it. The advantage of this is that I can use two hands to work and the magnet will hold the hinge for me. Obviously, you can do this just using something like a small nail to slide the pin to the hinge end.

Gesture Finger Hand tool Wood Nail


Cut The Pin: Pictured is cutting off the extended pin.

Wood Finger Engineering Gas Metalworking


Stuff The Pin Back In Place: Using the pin punch, slide the pin back inside the knuckle of the hinge.

Hand tool Wood Tool Metalworking hand tool Gas


Crimp The Hinge Ends: Using a ball peen hammer and a small anvil lightly tap the hinge ends to crimp them closed and prevent the pin from slipping out of the knuckle. You may need to resand the hinge if you have a burr or sharp end after peening the ends of the hinge.

Hand Wood Finger Gas Machine


Painting The Ends: Since I use steel hinges, they would soon rust if they were not coated. I spray paint the ends to prevent this. Notice that everything you need to do this job is at one station. (See the holders for pliers and hammer?) Once I walk up to this station, I can make a hinge that will fit a box without taking a step. With practice and this station it takes about 10 minutes to size, cut, smooth, shorten the pin, crimp the knuckle, re-smooth, and paint the ends of a hinge. Now, how do you mortise and install these hinges in a box? Read the next chapter of this blog. "How To Install a Hinge" to find out.

I'll leave you with a few pictures of the hinge station itself. I finished building it this spring and it has seen hard use in a short time. This summer I'll make the final refinements and paint it to make it pretty.
.
.

My Hinge Station (The Chop Smith)
.
Wood Workbench Engineering Machine tool Machine


Everything is at hand. Even a trash can.

Wood Hand tool Brush Tool Gas


Tools
Wood Gas Cylinder Metal Machine

Paint and New Hinges
Wood Bumper Gas Machine Metal

Pin punch, Anvil, Magnetic Hinge Holder
Wood Gas Automotive tire Machine Auto part

Belt Grinder
Wood Workbench Tool Gas Hardwood

Modified Metal Cutting Band Saw (It sports a 1/2 HP motor)
 

Attachments

#44 ·
Separating The Top and Cutting a Hinge to Fit

How do you make a hinge and fit it in a box so that it looks like this when you are done?

Rectangle Wood Box Bag Cosmetics


You Could Use This!...My Hinge Station or a Hack Saw

Wood Workbench Engineering Machine tool Machine

.
.

Just Browsing? If you want to casually breeze through this just read the dark print and look at the pictures. For more serious readers, I have included details in the fine print.

Economics: Price is a major consideration if you are making boxes for sale. I simply can't afford to put $35 or more into a set of fine brass hinges and make any money on the boxes I sell. I wish I could. So I choose to use piano hinges that have been cut from a 4 foot length so they fit the particular box that I am working on at the moment. I use 1 1/16 inch wide brass coated steel hinges and try to keep my side thicknesses at 5/8 of an inch. Steel plated piano hinges are my compromise between economy. appearance, and function.

Reasoning: Other than money why this choice? I am trying to make boxes that will still be in use 100 years from now. With modern glues and careful joinery, I may have a chance. Piano hinges are the most stable and strongest way I know to join the lid to the bottom of a box and allow it to swing open. Other styles of boxes lend themselves well to pin hinges and pivot hinges on the outside of the box, but I have not made many of that style of box.

The Process In Pictures: It may take some scrolling, but I have tried to have a picture for each step.
.
.
.

Separating The Top:

Brown Wood Gas Tints and shades Wood stain


Set Your Blade Height: First use a scrap from the original board you started with to set your saw blade to slightly beyond the thickness of the side of your box. (If you lost the scrap you can set the blade by the edge showing on top or bottom, but it is more difficult to be accurate, especially if you rounded those edges as I have here.) Note the shop-made zero clearance insert…good idea.

Packing materials Wood Package delivery Hardwood Carton


Set Your Fence: Now set your fence to the proper position to cut your lid off. Always keep the lid to the left of your blade. Cut through the two long sides, but lower your blade so you don't quite cut through with the end cuts. Notice that I marked the back in chalk so I can be sure to put it back together properly after it is separated. With close grain patterns you often can't tell the front from the back until you apply a finish. Remember! For the two end cuts lower the blade enough so it doesn't cut all the way through the box side. This lowering keeps the blade from being pinched by the box. When the box pinches the saw blade a lot of bad things happen to the box and maybe to you as well.

Wood Gesture Wood stain Varnish Hardwood


Finish Cutting the Ends: Now cut the remaining sliver away in the two end cuts with a box cutter and separate the lid from the bottom.

.
.
.

Making The Hinge:
.
.

Hand Wood Finger Wood stain Hardwood


Size It: The first step is to set your hinge on the box and determine how long it should be. Obviously you don't want it to end in the middle of a screw hole, but you do want it to be close to the inside edge of the box.

Hand Wood Finger Tool Wood stain


Cut The Hinge: I took an old metal-cutting band saw and made it into a tool specifically for this job, but you can cut it by hand using a hack saw.

Hand Wood Finger Gas Musical instrument accessory


Smoothing And Rounding: I use a cheap ($35) one inch belt sander that I bought from Grizzly for this. But you can use any sander or even just do it by hand. Just remove the burrs and any saw marks. I round off the inside and outside corners so they won't be too sharp and cut customers.

Hand Wood Finger Gas Stonemason's hammer


Shorten The Pin: Over time the hinge's pin would work loose and stick out as a sharp point. To prevent this I use a small punch to make the pin slide to one end. Shown here is a specialized tool. It is a magnet over a metal bar with a hole in it. The advantage of this is that I can use two hands to work and the magnet will hold the hinge for me. Obviously, you can do this just using something like a small nail to slide the pin to the hinge end.

Gesture Finger Hand tool Wood Nail


Cut The Pin: Pictured is cutting off the extended pin.

Wood Finger Engineering Gas Metalworking


Stuff The Pin Back In Place: Using the pin punch, slide the pin back inside the knuckle of the hinge.

Hand tool Wood Tool Metalworking hand tool Gas


Crimp The Hinge Ends: Using a ball peen hammer and a small anvil lightly tap the hinge ends to crimp them closed and prevent the pin from slipping out of the knuckle. You may need to resand the hinge if you have a burr or sharp end after peening the ends of the hinge.

Hand Wood Finger Gas Machine


Painting The Ends: Since I use steel hinges, they would soon rust if they were not coated. I spray paint the ends to prevent this. Notice that everything you need to do this job is at one station. (See the holders for pliers and hammer?) Once I walk up to this station, I can make a hinge that will fit a box without taking a step. With practice and this station it takes about 10 minutes to size, cut, smooth, shorten the pin, crimp the knuckle, re-smooth, and paint the ends of a hinge. Now, how do you mortise and install these hinges in a box? Read the next chapter of this blog. "How To Install a Hinge" to find out.

I'll leave you with a few pictures of the hinge station itself. I finished building it this spring and it has seen hard use in a short time. This summer I'll make the final refinements and paint it to make it pretty.
.
.

My Hinge Station (The Chop Smith)
.
Wood Workbench Engineering Machine tool Machine


Everything is at hand. Even a trash can.

Wood Hand tool Brush Tool Gas


Tools
Wood Gas Cylinder Metal Machine

Paint and New Hinges
Wood Bumper Gas Machine Metal

Pin punch, Anvil, Magnetic Hinge Holder
Wood Gas Automotive tire Machine Auto part

Belt Grinder
Wood Workbench Tool Gas Hardwood

Modified Metal Cutting Band Saw (It sports a 1/2 HP motor)
That's the way to keep production up, organization. You've got a great space there that you've worked all the bugs out of, thanks for sharing it with us.
 

Attachments

#57 ·
Mortising Piano Hinges In a Box (An Easy Method)

Overview: In the last blog I detailed how to separate the top from the box and how to start with a long piano hinge then size, cut, polish, round, crimp, smooth, and paint the hinge so it will fit any size of box.

In this chapter I will explain how to install a piano hinge in a box. We will go through how to mortise, fit and fasten the hinge. The essential tools are: router table, small try square, vix bit, drill and impact driver. If all goes well, it should look like this when you are done.

Rectangle Wood Box Bag Cosmetics


Centering: Exactly center the hinge on the back of the box using a try square. Move a small try square from left side to right side. Adjust the blade of the try square in and out until the end blade of the try square just kisses the hinge on both sides. No real measuring is needed.

Wood Wood stain Hardwood Rectangle Gas


Wood Finger Wood stain Hardwood Gas


It may take a few tries making fine adjustments and going back an forth, but when you are finished you will have your hinge in the exact center. Now lock down the stock of your try square to preserve that measurement. We are going to use this measurement to set up the router fence.

Hand Wood Finger Gesture Engineering


Fence Location: As you can see I use a simple clamping straight edge as a fence for this. It is light, easy to move and change, and stays in place. (Remember, when you are setting a router fence like this, all that matters is the distance between the fence and the cutter. If it isn't straight so what? The bit is round so straight isn't important, distance is.) With the head of the straight edged cutter bit turned so the longest point is closest to the fence, align the cutter with the stock and transfer the measurement you took when centering your hinge to be the distance between the fence and the point of the cutter. This needs to be an exact match and you should sight down the head to get the exact point of the cutter at the edge of your try square head. Bring your fence over until it touches the blade of your try square and lock the fence in place. With good light and some care this can be a very exact measurement…and it needs to be.

Table Wood Wood stain Finger Paint


Cutting the Mortise: What I didn't think to picture was setting the bit height. Put your hinge on the table and raise the bit until the top of the bit is at the exact center of the pin of your hinge. Since this mortising is all I do on this table, I leave it set for the hinges I buy.

Now bring your box down the fence to cut a mortise. Notice two things: One, I marked the back side with chalk so I don't screw up and cut the mortise on the front side. Two, be sure your table and fence are free of sawdust. Any dust between the box and the fence will throw off your measurements. Now reverse the box and cut the other end of your mortise going along the fence from the opposite side of the bit. Thus, you have cut both ends of your mortise and now all you do is freehand cut the waste wood between the two exact ends.

Hand Wood Gesture Wood stain Flooring


This shows cutting between the end cuts. Be careful not to cut too far. Listening for the end of the cut helps. (Of course if you were using 3/4 hinges and a 3/4 inch bit, you would be done and not need to cut out the waste.)

Hand Wood Finger Wood stain Hardwood


Repeat the same process for cutting the top. First cut the ends…

Hand Wood Gesture Finger Wood stain


Then cut the waste between the two end cuts.

Wood Wood stain Hardwood Rectangle Tool


The Completed Mortise: This shot shows the top and the bottom of the box held together so you can see the completed mortise. The ends match nicely, the mortise is evenly cut, and now you are ready to insert the hinge.

Wood Finger Wood stain Hardwood Nail


Install The Hinge: Here you see the hinge set in the mortise. If you have worked carefully (and are a little lucky) the hinge will be a nice snug fit. Install the hinge starting on the bottom of the box. This shows the reason. You can reach across the box and use your wrists and palms to hold the box down while you work. This is a good time to sand the inside and outside edges of your mortise to be sure there are no splinters to catch unwary fingers (like yours)...before you start putting the hinge in place.

Microphone Wood Audio equipment Microphone stand Human leg


Use a Vix Bit: A Vix bit is a must. This bit centers the screw-hole you are drilling in the center of the hole in the hinge. Don't just set the Vix bit in the hole and jam the bit into the wood. Let the bit spin in the screw hole then while it is spinning lower your bit into the wood. Spinning the bit first lets it get better seated and you will have better results.

Wood Floor Wood stain Hardwood Flooring


Drill One Or Two Holes In the Bottom: First put just one or two screws and screw holes in the top. Don't drill all the holes yet. If you missed the mark you can still make adjustments using the other holes to straighten it up.

Wood Wood stain Musical instrument accessory Folk instrument Musical instrument


Put One or Two Holes in the Top: Check your fit. If it is just very slightly off you can sand the outside of the box so they match exactly. But if the sides and front don't match well, remove one or two screws and get the fit right. Here again it is a help if you have a back-rest to lean the bottom against so you can hold it in place and it gives you two free hands to work with.

Hand Wood Rectangle Gesture Finger


Check the Fit: See if the sides and front match. If they do match, carefully open the box and install a few more screws and then check the fit again when you work on the bottom. It helps if your work station has some kind of rest to let the open box lean against so you have two free hands to work with.

Wood Communication Device Gadget Finger Portable communications device


Now drill and install all your remaining screws. I like to use an impact driver. It takes a bit to get the right touch with this tool, but it is far less likely to strip out the screw heads and brings the screws down snuggly.

Brown Wood Rectangle Wood stain Hardwood


Hinge Completed: If all has gone well, your finished hinge will look like this on the outside of your box. As you can see here, I sand the back edges at the back corner to be sure the box will swing to 90 degrees

The next time I am daft enough to take on a pictured blog like this I will be writing about this sanding station. Who knew it would take 6 sanders to make a box? But it is much quicker than changing Velcro paper.

Automotive tire Helmet Automotive design Gas Personal protective equipment
 

Attachments

#58 ·
Mortising Piano Hinges In a Box (An Easy Method)

Overview: In the last blog I detailed how to separate the top from the box and how to start with a long piano hinge then size, cut, polish, round, crimp, smooth, and paint the hinge so it will fit any size of box.

In this chapter I will explain how to install a piano hinge in a box. We will go through how to mortise, fit and fasten the hinge. The essential tools are: router table, small try square, vix bit, drill and impact driver. If all goes well, it should look like this when you are done.

Rectangle Wood Box Bag Cosmetics


Centering: Exactly center the hinge on the back of the box using a try square. Move a small try square from left side to right side. Adjust the blade of the try square in and out until the end blade of the try square just kisses the hinge on both sides. No real measuring is needed.

Wood Wood stain Hardwood Rectangle Gas


Wood Finger Wood stain Hardwood Gas


It may take a few tries making fine adjustments and going back an forth, but when you are finished you will have your hinge in the exact center. Now lock down the stock of your try square to preserve that measurement. We are going to use this measurement to set up the router fence.

Hand Wood Finger Gesture Engineering


Fence Location: As you can see I use a simple clamping straight edge as a fence for this. It is light, easy to move and change, and stays in place. (Remember, when you are setting a router fence like this, all that matters is the distance between the fence and the cutter. If it isn't straight so what? The bit is round so straight isn't important, distance is.) With the head of the straight edged cutter bit turned so the longest point is closest to the fence, align the cutter with the stock and transfer the measurement you took when centering your hinge to be the distance between the fence and the point of the cutter. This needs to be an exact match and you should sight down the head to get the exact point of the cutter at the edge of your try square head. Bring your fence over until it touches the blade of your try square and lock the fence in place. With good light and some care this can be a very exact measurement…and it needs to be.

Table Wood Wood stain Finger Paint


Cutting the Mortise: What I didn't think to picture was setting the bit height. Put your hinge on the table and raise the bit until the top of the bit is at the exact center of the pin of your hinge. Since this mortising is all I do on this table, I leave it set for the hinges I buy.

Now bring your box down the fence to cut a mortise. Notice two things: One, I marked the back side with chalk so I don't screw up and cut the mortise on the front side. Two, be sure your table and fence are free of sawdust. Any dust between the box and the fence will throw off your measurements. Now reverse the box and cut the other end of your mortise going along the fence from the opposite side of the bit. Thus, you have cut both ends of your mortise and now all you do is freehand cut the waste wood between the two exact ends.

Hand Wood Gesture Wood stain Flooring


This shows cutting between the end cuts. Be careful not to cut too far. Listening for the end of the cut helps. (Of course if you were using 3/4 hinges and a 3/4 inch bit, you would be done and not need to cut out the waste.)

Hand Wood Finger Wood stain Hardwood


Repeat the same process for cutting the top. First cut the ends…

Hand Wood Gesture Finger Wood stain


Then cut the waste between the two end cuts.

Wood Wood stain Hardwood Rectangle Tool


The Completed Mortise: This shot shows the top and the bottom of the box held together so you can see the completed mortise. The ends match nicely, the mortise is evenly cut, and now you are ready to insert the hinge.

Wood Finger Wood stain Hardwood Nail


Install The Hinge: Here you see the hinge set in the mortise. If you have worked carefully (and are a little lucky) the hinge will be a nice snug fit. Install the hinge starting on the bottom of the box. This shows the reason. You can reach across the box and use your wrists and palms to hold the box down while you work. This is a good time to sand the inside and outside edges of your mortise to be sure there are no splinters to catch unwary fingers (like yours)...before you start putting the hinge in place.

Microphone Wood Audio equipment Microphone stand Human leg


Use a Vix Bit: A Vix bit is a must. This bit centers the screw-hole you are drilling in the center of the hole in the hinge. Don't just set the Vix bit in the hole and jam the bit into the wood. Let the bit spin in the screw hole then while it is spinning lower your bit into the wood. Spinning the bit first lets it get better seated and you will have better results.

Wood Floor Wood stain Hardwood Flooring


Drill One Or Two Holes In the Bottom: First put just one or two screws and screw holes in the top. Don't drill all the holes yet. If you missed the mark you can still make adjustments using the other holes to straighten it up.

Wood Wood stain Musical instrument accessory Folk instrument Musical instrument


Put One or Two Holes in the Top: Check your fit. If it is just very slightly off you can sand the outside of the box so they match exactly. But if the sides and front don't match well, remove one or two screws and get the fit right. Here again it is a help if you have a back-rest to lean the bottom against so you can hold it in place and it gives you two free hands to work with.

Hand Wood Rectangle Gesture Finger


Check the Fit: See if the sides and front match. If they do match, carefully open the box and install a few more screws and then check the fit again when you work on the bottom. It helps if your work station has some kind of rest to let the open box lean against so you have two free hands to work with.

Wood Communication Device Gadget Finger Portable communications device


Now drill and install all your remaining screws. I like to use an impact driver. It takes a bit to get the right touch with this tool, but it is far less likely to strip out the screw heads and brings the screws down snuggly.

Brown Wood Rectangle Wood stain Hardwood


Hinge Completed: If all has gone well, your finished hinge will look like this on the outside of your box. As you can see here, I sand the back edges at the back corner to be sure the box will swing to 90 degrees

The next time I am daft enough to take on a pictured blog like this I will be writing about this sanding station. Who knew it would take 6 sanders to make a box? But it is much quicker than changing Velcro paper.

Automotive tire Helmet Automotive design Gas Personal protective equipment
Excellent tutorial Al. The time spent, is well spent.
 

Attachments

#74 ·
Making Great $5 Band Clamps!

Overview: If you are going to make boxes there is no substitute for good band clamps. They pull all eight joint cuts together and tend to average out any cuts that are slightly off. I use two clamps on each box. They are expensive to buy, but cheap if you make your own. When in use, they look like this. These are really cranked down to pull all the joints tight. (A big thanks to Derrick who patiently helped me picture each step in this process.)

Blue Wood Rectangle Fastener Gas


Hint: To make this a quick read just scan the dark print and look at the pictures. You can come back for the details if you need them.

I will try to explain this process in two languages…English and pictures. Any comments or suggestions will be appreciated.

Start with a package of these. Cheap tie-downs from Sam's or an auto store. Buy a set that has rubber covered crank handles as they are much easier on your hands when you tighten them.

Toy Hood Bumper Automotive design Font


General Idea: What we are going to do is remove the hook on the long strap. Throw away the small strap. Grind away the rivet from the frame, and re-position the long strap so the looped end that held the hook is now re-connected with a bolt where the short strap was connected, and re-thread the long strap through the eye in the ratchet mechanism. If this is confusing…just follow the pictured steps.

Hand tool Metalworking hand tool Tool Wood Gas


Here are the tools I used for this job. You don't need all of these, but they are useful if you have them. A vise, angle grinder (you could use an emery wheel or file), ball peen hammer, small vise grips, drift punch, scissors, channel locks, 1 inch x 1/4 inch bolt, a couple of wrenches to fit the bolt and nut, and a big screwdriver. If you have been looking for a use for that great big screwdriver that came in the Craftsman set you got for Christmas…this is your chance to finally use that sucker!

Hand Plant Light Carabiner Finger


Start by cutting away the short strap and hook with the scissors. DO NOT get carried away and cut the loop on the long strap! We will need this for later.

Calipers Automotive lighting Motor vehicle Camera accessory Finger


Now, you have the fame with no straps attached.

Automotive tire Hood Finger Bumper Fender


Twist the hook on the longer strap to spring the eye of this hook slightly so you can slip the loop off the hook. Told you you could finally get to use that great big screwdriver. (This is much easier and faster than cutting the hook itself.)

Sleeve Gesture Finger Grass Thumb


The next modification is to remove the rivet holding the long strap onto the ratchet mechanism. We are going to grind off the head of the rivet to remove it without harming the ratchet frame.

Hand Sleeve Gesture Finger Revolver


Use the channel locks to bend the frame enough so the rivet head stands proud of the frame itself.

Hand Finger Gesture Motor vehicle Grass


I found it useful to use the vise grips to hold the rivet up while the frame was clamped in the regular vise.

Plant Glove Saw Grass Handheld power drill


With the frame clamped back in the regular vise grind away the head of the rivet.

Saw chain Chainsaw Wood Tool Grass


Use the hammer and a punch to remove the rivet from the frame.

Musical instrument Guitar accessory String instrument accessory Wind instrument Brass instrument


With the channel locks bend the frame back into its original position making sure the ratchet can turn freely and the spring loaded catch mechanism works freely too.

Hand Wood Finger Revolver Thumb


Now we are going to re-attach the loop from the long strap (This loop originally held a hook we removed.) We will bolt it in place back on the frame using the holes from where the short strap was originally held in place by the rivet.

Hand Finger Automotive tire Thumb Wrist


Here you see that the original rivet has been replaced by a 1/4 inch bolt and nut.

Revolver Grass Gas Personal protective equipment Bicycle part


Back to the vise putting the bolt head in the vise jaws.

Safety glove Grinding Gas Engineering Angle grinder


Grind away most of the bolt sticking out beyond the frame, but leave about 1/8 of and inch to peen down. Caution: don't let the bolt get so hot you melt the nylon strap. If you melt through the loop the clamp can't work. (The voice of experience speaking here.)

Hand tool Wood Metalworking hand tool Finger Tool


Peening the threaded end means you batter what is sticking out beyond the nut spreading the end of the bolt so the nut won't be able to come off.

Hand Gesture Finger Thumb Wrist


Final step…take all the twists out of the strap and thread the loose end of the strap through the eye in the ratchet mechanism. You need to feed the strap from the bottom of the clamp to the top so it will draw around the box as you tighten it up.
I keep my supply of these straps hanging on my glue-up table. They are color coded for length since it is awkward gluing up a small box with a longer strap. Hint: I usually put a small block of wood under the ratchet body to prevent denting the wood when the clamp is tightened.

Blue Wood Rectangle Fastener Gas


Thanks for working through all these steps with me. This post was really tedious for me, but hopefully it will cover any problems you have with the process. If you have questions ask, please Any comments or suggestions are always appreciated.
 

Attachments

#75 ·
Making Great $5 Band Clamps!

Overview: If you are going to make boxes there is no substitute for good band clamps. They pull all eight joint cuts together and tend to average out any cuts that are slightly off. I use two clamps on each box. They are expensive to buy, but cheap if you make your own. When in use, they look like this. These are really cranked down to pull all the joints tight. (A big thanks to Derrick who patiently helped me picture each step in this process.)

Blue Wood Rectangle Fastener Gas


Hint: To make this a quick read just scan the dark print and look at the pictures. You can come back for the details if you need them.

I will try to explain this process in two languages…English and pictures. Any comments or suggestions will be appreciated.

Start with a package of these. Cheap tie-downs from Sam's or an auto store. Buy a set that has rubber covered crank handles as they are much easier on your hands when you tighten them.

Toy Hood Bumper Automotive design Font


General Idea: What we are going to do is remove the hook on the long strap. Throw away the small strap. Grind away the rivet from the frame, and re-position the long strap so the looped end that held the hook is now re-connected with a bolt where the short strap was connected, and re-thread the long strap through the eye in the ratchet mechanism. If this is confusing…just follow the pictured steps.

Hand tool Metalworking hand tool Tool Wood Gas


Here are the tools I used for this job. You don't need all of these, but they are useful if you have them. A vise, angle grinder (you could use an emery wheel or file), ball peen hammer, small vise grips, drift punch, scissors, channel locks, 1 inch x 1/4 inch bolt, a couple of wrenches to fit the bolt and nut, and a big screwdriver. If you have been looking for a use for that great big screwdriver that came in the Craftsman set you got for Christmas…this is your chance to finally use that sucker!

Hand Plant Light Carabiner Finger


Start by cutting away the short strap and hook with the scissors. DO NOT get carried away and cut the loop on the long strap! We will need this for later.

Calipers Automotive lighting Motor vehicle Camera accessory Finger


Now, you have the fame with no straps attached.

Automotive tire Hood Finger Bumper Fender


Twist the hook on the longer strap to spring the eye of this hook slightly so you can slip the loop off the hook. Told you you could finally get to use that great big screwdriver. (This is much easier and faster than cutting the hook itself.)

Sleeve Gesture Finger Grass Thumb


The next modification is to remove the rivet holding the long strap onto the ratchet mechanism. We are going to grind off the head of the rivet to remove it without harming the ratchet frame.

Hand Sleeve Gesture Finger Revolver


Use the channel locks to bend the frame enough so the rivet head stands proud of the frame itself.

Hand Finger Gesture Motor vehicle Grass


I found it useful to use the vise grips to hold the rivet up while the frame was clamped in the regular vise.

Plant Glove Saw Grass Handheld power drill


With the frame clamped back in the regular vise grind away the head of the rivet.

Saw chain Chainsaw Wood Tool Grass


Use the hammer and a punch to remove the rivet from the frame.

Musical instrument Guitar accessory String instrument accessory Wind instrument Brass instrument


With the channel locks bend the frame back into its original position making sure the ratchet can turn freely and the spring loaded catch mechanism works freely too.

Hand Wood Finger Revolver Thumb


Now we are going to re-attach the loop from the long strap (This loop originally held a hook we removed.) We will bolt it in place back on the frame using the holes from where the short strap was originally held in place by the rivet.

Hand Finger Automotive tire Thumb Wrist


Here you see that the original rivet has been replaced by a 1/4 inch bolt and nut.

Revolver Grass Gas Personal protective equipment Bicycle part


Back to the vise putting the bolt head in the vise jaws.

Safety glove Grinding Gas Engineering Angle grinder


Grind away most of the bolt sticking out beyond the frame, but leave about 1/8 of and inch to peen down. Caution: don't let the bolt get so hot you melt the nylon strap. If you melt through the loop the clamp can't work. (The voice of experience speaking here.)

Hand tool Wood Metalworking hand tool Finger Tool


Peening the threaded end means you batter what is sticking out beyond the nut spreading the end of the bolt so the nut won't be able to come off.

Hand Gesture Finger Thumb Wrist


Final step…take all the twists out of the strap and thread the loose end of the strap through the eye in the ratchet mechanism. You need to feed the strap from the bottom of the clamp to the top so it will draw around the box as you tighten it up.
I keep my supply of these straps hanging on my glue-up table. They are color coded for length since it is awkward gluing up a small box with a longer strap. Hint: I usually put a small block of wood under the ratchet body to prevent denting the wood when the clamp is tightened.

Blue Wood Rectangle Fastener Gas


Thanks for working through all these steps with me. This post was really tedious for me, but hopefully it will cover any problems you have with the process. If you have questions ask, please Any comments or suggestions are always appreciated.
Smart modification!
 

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#101 ·
Process For Setting Depth for Spline Cuts

Setting up saw blades for slot cuts in box corners.

Here is a quick way to set up your saw for cutting spline slots using a spline cutting jig and a dado blade. This method involves no measuring and take only a minute or two.

The trick is to use brass set up bars.

I keep my set close to the dado saw in my shop.

Hand tool Wood Metalworking hand tool Gas Mallet


Hold the largest bar on a 45 degree angle on the corner of the box.

Hand Wood Finger Wood stain Hardwood


Add other bars until you get a combination that is just a little under the width of the box corner.

Hand Wood Finger Wood stain Hardwood


Now move these bars to the saw blade and crank it up or down until you have matched the height of the saw blade and the height of the set up bars. A finger touch will tell you when they are even. The blade tooth needs to be top dead center when you measure.

Wood Floor Flooring Amber Wood stain


Now you can cut your spline slots without fear of cutting through your box corners. Have fun and look at my blog tutorial on how to build a slot cutting jig.
 

Attachments

#102 ·
Process For Setting Depth for Spline Cuts

Setting up saw blades for slot cuts in box corners.

Here is a quick way to set up your saw for cutting spline slots using a spline cutting jig and a dado blade. This method involves no measuring and take only a minute or two.

The trick is to use brass set up bars.

I keep my set close to the dado saw in my shop.

Hand tool Wood Metalworking hand tool Gas Mallet


Hold the largest bar on a 45 degree angle on the corner of the box.

Hand Wood Finger Wood stain Hardwood


Add other bars until you get a combination that is just a little under the width of the box corner.

Hand Wood Finger Wood stain Hardwood


Now move these bars to the saw blade and crank it up or down until you have matched the height of the saw blade and the height of the set up bars. A finger touch will tell you when they are even. The blade tooth needs to be top dead center when you measure.

Wood Floor Flooring Amber Wood stain


Now you can cut your spline slots without fear of cutting through your box corners. Have fun and look at my blog tutorial on how to build a slot cutting jig.
thanks for advice ive yet to try a spline n boxes but want to try this will help
 

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#110 ·
Cutting the Corner 45 Degree Angles

A Quick, Accurate Way To 45 Your Corners

Wood Wood stain Creative arts Hardwood Flooring


If you build boxes at all, eventually you tire of cranking your blade from 90 degrees to 45 degrees and back…I did. So I built this simple jig, and now I can cut all 8 ends of a box accurately in about 5 minutes, AND STILL LEAVE MY TABLE SAW SET AT 90 DEGREES.

Assumption: I am assuming that you have already laid out the board for your sides and have cut all four sides of your box to length. Short side, long side, short side, long side and have cut a dado slot in these boards that will accept the bottom board of your finished box.

Wood Wood stain Creative arts Hardwood Flooring


(above) The key to efficiency is this jig. It is designed to hold the box side on a 45 degree angle. It has an adjustable stop running vertically in a track, and a clamp to hold it while you run it across the blade. Used properly, your hands will be well out of the way while this is happening.

IT IS IMPERATIVE THAT YOU WEAR EYE PROTECTION WHEN YOU USE THIS JIG. THE SMALL CUT OFF FROM THE DADO GROOVE CAN REALLY FLY AROUND THE SHOP.

Wood Hardwood Wood stain Publication Plywood


(above) To operate the jig, put the bottom dado cut up and clamp the box side in the jig. Feel under the clamped side to see that just a little of the bottom edge of the board extends just beyond the blade-side part of the jig. Now, BRING THE SLIDING STOP DOWN TO CONTACT THE TOP EDGE OF THE CLAMPED SIDE AND LOCK THE STOP. The stop is the white plastic piece with the knob in the sliding track.

Use the clamp lever to be sure the box side is firmly clamped and seated properly in the jig.

Wood Publication Hardwood Wood stain Flooring


Now use the jig to slide the jig and board over the saw blade. KEEP YOUR HANDS WELL INSIDE AND TO THE BACK OF THE JIG. USE THE HANDLE.

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(above) Now slide the jig well back on your table saw so the board is well back and out of the way of the blade. To be safe turn off the saw. Release the clamp, spin the side around and put the newly cut edge against the stop.
Then cut the opposite end too.

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(above) This shows the two ends cut. IMPORTANT: DON'T MOVE THE STOP. WHILE YOU HAVE THIS SETTING, CUT THE OPPOSING SIDE OF THE BOX…NOW BOTH OPPOSING SIDES WILL BE IDENTICAL IN LENGTH.
If you are making a square box leave the stop in place and cut the next two sides. If it is oblong, reset the stop for the next two sides and cut them.

Wood Wood stain Hardwood Flooring Gas


Jig Building Hints:

(above) This shot shows the bottom of the jig. It runs on a single guide. I prefer UHMW (ultra high molecular weight) plastic for runners. These guides don't swell or shrink and are self lubricating. If you let the guide extend a bit beyond the back of the jig it makes it easy to align the guide with the table saw slot.

Wood Hardwood Wood stain Flooring Rectangle


(above) This is not a great shot, but you can see the clamping board is supported by an angle cut 2×6.

Additional Suggestions:

While I used a dual clamp modified to hold the clamp in the the jig with one side, and the box side to be cut is clamped on the other side, you could use a simple clamp to hold the box side and screw it securely to fasten it to the jig.

Wood Flooring Floor Hardwood Wood stain


(above) I have found that having the saw-side edge elevated about an inch above the table allows the cut of edges to drop in the center of the blade and the cutoffs are less likely to be thrown by a moving blade. A ZERO CLEARANCE INSERT IS A MUST SO THE SMALL CUT OFFS DON'T GET WEDGED BETWEEN A MOVING BLADE AND THE INSERT.

Recess your clamp so it is even with the angled top of the jig.

Be careful not to let the angled edge of the cut and spun board slip under your stop. If I build another of these, I'll put a dado and a finger on the stop to prevent the angled side from slipping under the stop.

Design your stop so it stays square to the vertical track.

In practice this jig is quick and easy to use and the build is not really complex. It saves me a ton of time.
 

Attachments

#111 ·
Cutting the Corner 45 Degree Angles

A Quick, Accurate Way To 45 Your Corners

Wood Wood stain Creative arts Hardwood Flooring


If you build boxes at all, eventually you tire of cranking your blade from 90 degrees to 45 degrees and back…I did. So I built this simple jig, and now I can cut all 8 ends of a box accurately in about 5 minutes, AND STILL LEAVE MY TABLE SAW SET AT 90 DEGREES.

Assumption: I am assuming that you have already laid out the board for your sides and have cut all four sides of your box to length. Short side, long side, short side, long side and have cut a dado slot in these boards that will accept the bottom board of your finished box.

Wood Wood stain Creative arts Hardwood Flooring


(above) The key to efficiency is this jig. It is designed to hold the box side on a 45 degree angle. It has an adjustable stop running vertically in a track, and a clamp to hold it while you run it across the blade. Used properly, your hands will be well out of the way while this is happening.

IT IS IMPERATIVE THAT YOU WEAR EYE PROTECTION WHEN YOU USE THIS JIG. THE SMALL CUT OFF FROM THE DADO GROOVE CAN REALLY FLY AROUND THE SHOP.

Wood Hardwood Wood stain Publication Plywood


(above) To operate the jig, put the bottom dado cut up and clamp the box side in the jig. Feel under the clamped side to see that just a little of the bottom edge of the board extends just beyond the blade-side part of the jig. Now, BRING THE SLIDING STOP DOWN TO CONTACT THE TOP EDGE OF THE CLAMPED SIDE AND LOCK THE STOP. The stop is the white plastic piece with the knob in the sliding track.

Use the clamp lever to be sure the box side is firmly clamped and seated properly in the jig.

Wood Publication Hardwood Wood stain Flooring


Now use the jig to slide the jig and board over the saw blade. KEEP YOUR HANDS WELL INSIDE AND TO THE BACK OF THE JIG. USE THE HANDLE.

Wood Textile Wood stain Hardwood Rectangle


(above) Now slide the jig well back on your table saw so the board is well back and out of the way of the blade. To be safe turn off the saw. Release the clamp, spin the side around and put the newly cut edge against the stop.
Then cut the opposite end too.

Wood Flooring Floor Hardwood Wood stain


(above) This shows the two ends cut. IMPORTANT: DON'T MOVE THE STOP. WHILE YOU HAVE THIS SETTING, CUT THE OPPOSING SIDE OF THE BOX…NOW BOTH OPPOSING SIDES WILL BE IDENTICAL IN LENGTH.
If you are making a square box leave the stop in place and cut the next two sides. If it is oblong, reset the stop for the next two sides and cut them.

Wood Wood stain Hardwood Flooring Gas


Jig Building Hints:

(above) This shot shows the bottom of the jig. It runs on a single guide. I prefer UHMW (ultra high molecular weight) plastic for runners. These guides don't swell or shrink and are self lubricating. If you let the guide extend a bit beyond the back of the jig it makes it easy to align the guide with the table saw slot.

Wood Hardwood Wood stain Flooring Rectangle


(above) This is not a great shot, but you can see the clamping board is supported by an angle cut 2×6.

Additional Suggestions:

While I used a dual clamp modified to hold the clamp in the the jig with one side, and the box side to be cut is clamped on the other side, you could use a simple clamp to hold the box side and screw it securely to fasten it to the jig.

Wood Flooring Floor Hardwood Wood stain


(above) I have found that having the saw-side edge elevated about an inch above the table allows the cut of edges to drop in the center of the blade and the cutoffs are less likely to be thrown by a moving blade. A ZERO CLEARANCE INSERT IS A MUST SO THE SMALL CUT OFFS DON'T GET WEDGED BETWEEN A MOVING BLADE AND THE INSERT.

Recess your clamp so it is even with the angled top of the jig.

Be careful not to let the angled edge of the cut and spun board slip under your stop. If I build another of these, I'll put a dado and a finger on the stop to prevent the angled side from slipping under the stop.

Design your stop so it stays square to the vertical track.

In practice this jig is quick and easy to use and the build is not really complex. It saves me a ton of time.
Wow, that's quite an impressive invention for 45 deg corners. It looks to be sturdy and well used.

Here's a picture of the one I use for my 45 deg box corners.

Wood Wood stain Hardwood Plank Flooring
 

Attachments

#133 ·
Making an Attached Top Box

I make two kinds of box tops.

Brown Rectangle Wood Amber Wood stain


Boxes with inset tops (above) where the the top floats in a dadoed groove that runs around the sides,

Wood Rectangle Wood stain Hardwood Varnish


and attached tops where the top is glued directly onto the sides of the box. This tutorial will feature the attached top method, and a press design to help with this process.

Of course you can use clamps to hold the top on until the glue sets. But I prefer this press.

Wood Rectangle Toy Art Table


The press features 8 all-thread sections with a compression spring and plastic pipe around the all-thread at each corner. The springs are meant to hold the press open so you can place a box inside without having to fight with the press.

Toy Wood Art Table Trophy


So in this box the splines were glued in, the top has had glue applied and has had the rough top set on the box.

Wood Wooden block Rectangle Art Hardwood


To save time I often will install the splines and add the top then I can let both of them cure at the same time.

Now it gets set into the press and then I use an impact driver to tighten the nuts and apply even pressure to the top.

Wood Rectangle Tap Gas Wood stain


This version has a welded metal lattice that keeps the all-thread from turning and strengthens the bottom plywood.

Table Wood Hardwood Metal Wood stain


This shot demonstrates a 2×8 wooden cull added on top of the box top to make it easier to tighten in the press.

So now you can tighten the nuts with the impact driver and let the glue dry. Sure, you could use a ratchet wrench, but the impact driver is so much cooler and faster. I usually start at opposing corners and then move in and do a final re-tighten.

Table Wood Wood stain Machine tool Gas


When the press is not being used, the press and some culls are stored on the shelf above the glue-up table.
 

Attachments

#134 ·
Making an Attached Top Box

I make two kinds of box tops.

Brown Rectangle Wood Amber Wood stain


Boxes with inset tops (above) where the the top floats in a dadoed groove that runs around the sides,

Wood Rectangle Wood stain Hardwood Varnish


and attached tops where the top is glued directly onto the sides of the box. This tutorial will feature the attached top method, and a press design to help with this process.

Of course you can use clamps to hold the top on until the glue sets. But I prefer this press.

Wood Rectangle Toy Art Table


The press features 8 all-thread sections with a compression spring and plastic pipe around the all-thread at each corner. The springs are meant to hold the press open so you can place a box inside without having to fight with the press.

Toy Wood Art Table Trophy


So in this box the splines were glued in, the top has had glue applied and has had the rough top set on the box.

Wood Wooden block Rectangle Art Hardwood


To save time I often will install the splines and add the top then I can let both of them cure at the same time.

Now it gets set into the press and then I use an impact driver to tighten the nuts and apply even pressure to the top.

Wood Rectangle Tap Gas Wood stain


This version has a welded metal lattice that keeps the all-thread from turning and strengthens the bottom plywood.

Table Wood Hardwood Metal Wood stain


This shot demonstrates a 2×8 wooden cull added on top of the box top to make it easier to tighten in the press.

So now you can tighten the nuts with the impact driver and let the glue dry. Sure, you could use a ratchet wrench, but the impact driver is so much cooler and faster. I usually start at opposing corners and then move in and do a final re-tighten.

Table Wood Wood stain Machine tool Gas


When the press is not being used, the press and some culls are stored on the shelf above the glue-up table.
Awesome idea. Thanks for posting.
 

Attachments

#153 ·
Adding Splines To A Box

Adding Splines To a Box

Assumptions: I assume you have looked at the tutorial on making the splines themselves. The tutorial on cutting the splines slots with the jig there gives you a box that looks like this on the corner.

Furniture Wood Rectangle Box Hardwood


The next step is to glue the splines into the slots.

I should have pictured it, but I apply Tightbond's Carpenter's and Trim Glue to both the spline and the slot to assure there will be a good bond. This thicker glue is easier to work with, and much less runny, but it should be stored upside down to be sure it flows out when you squeeze the bottle.

Wood Shelving Paint Shelf Gas


Keeping your plumber's brushes in water will let you reuse these brushed for months. Dry them on a paper towel before you apply glue.

(below) This is a demonstration box that I use to explain to customers and students the steps involved in the spline process. All the spline slots are cut and the splines glued in place and smoothed down even with the sides of the box before the top of the box is separated and the hinge is added.

Furniture Wood Rectangle Packing materials Packaging and labeling


(above) This represents adding the splines in the demo box. There is a tutorial about gluing on a lid onto the box.

So now you have a rough box complete and it looks like this. (Below)

Wood Wooden block Rectangle Art Hardwood


Let's take a close look at the corners.

Wood Wood stain Natural material Hardwood Plank


As you can see the top and the splines are hanging over the sides. Now make to trip to the band saw and trim away most of that overhang without cutting into the side of the box.

After bandsawing away the overhanging top and splines, It will look something like this on the corners.

Furniture Table Wood Rectangle Wooden block


With the overhang removed you can now apply a large bearing-centered flush trim bit to remove the last of the overhanging top board. The alternative is to use rough grit sandpaper to remove the last of the spline overhang and top overhang and then make the sides of the box smooth and all surfaces flush. This will give you a box that looks something like this corner does.

For rounding over the corners and the top of the box your bearing has to ride on the smooth sides of the box. There is a real possibility of kickback when you are using a large roundover bit on a router. Use a starter pin, and consider making a light pass first, then another pass. Grip the box tightly and be very wary of kickback! You may be more comfortable using a flush trim bit on the first step of this route to smooth away the overhanging top after you have used the band saw. The flush trimming bit will remove the last of the top overhang on the side of the box or you can smooth away the last of the spline and top overhang with sanding using rough grits. This is the time you want to remove all of the glue squeeze out from gluing your splines into the slots.

Wood Rectangle Toy Window Wood stain


Next the top is separated and hinges are added and the corners are sanded and finished.

When all this is done you should have a box that looks something like this.

Plant Wood Rectangle Outdoor furniture Grass


To see other boxes click here.

PS

Making a tutorial with this many links and pictures is pretty exhausting. I hope it is of use to my fellow Lumber Jocks.
 

Attachments

#154 ·
Adding Splines To A Box

Adding Splines To a Box

Assumptions: I assume you have looked at the tutorial on making the splines themselves. The tutorial on cutting the splines slots with the jig there gives you a box that looks like this on the corner.

Furniture Wood Rectangle Box Hardwood


The next step is to glue the splines into the slots.

I should have pictured it, but I apply Tightbond's Carpenter's and Trim Glue to both the spline and the slot to assure there will be a good bond. This thicker glue is easier to work with, and much less runny, but it should be stored upside down to be sure it flows out when you squeeze the bottle.

Wood Shelving Paint Shelf Gas


Keeping your plumber's brushes in water will let you reuse these brushed for months. Dry them on a paper towel before you apply glue.

(below) This is a demonstration box that I use to explain to customers and students the steps involved in the spline process. All the spline slots are cut and the splines glued in place and smoothed down even with the sides of the box before the top of the box is separated and the hinge is added.

Furniture Wood Rectangle Packing materials Packaging and labeling


(above) This represents adding the splines in the demo box. There is a tutorial about gluing on a lid onto the box.

So now you have a rough box complete and it looks like this. (Below)

Wood Wooden block Rectangle Art Hardwood


Let's take a close look at the corners.

Wood Wood stain Natural material Hardwood Plank


As you can see the top and the splines are hanging over the sides. Now make to trip to the band saw and trim away most of that overhang without cutting into the side of the box.

After bandsawing away the overhanging top and splines, It will look something like this on the corners.

Furniture Table Wood Rectangle Wooden block


With the overhang removed you can now apply a large bearing-centered flush trim bit to remove the last of the overhanging top board. The alternative is to use rough grit sandpaper to remove the last of the spline overhang and top overhang and then make the sides of the box smooth and all surfaces flush. This will give you a box that looks something like this corner does.

For rounding over the corners and the top of the box your bearing has to ride on the smooth sides of the box. There is a real possibility of kickback when you are using a large roundover bit on a router. Use a starter pin, and consider making a light pass first, then another pass. Grip the box tightly and be very wary of kickback! You may be more comfortable using a flush trim bit on the first step of this route to smooth away the overhanging top after you have used the band saw. The flush trimming bit will remove the last of the top overhang on the side of the box or you can smooth away the last of the spline and top overhang with sanding using rough grits. This is the time you want to remove all of the glue squeeze out from gluing your splines into the slots.

Wood Rectangle Toy Window Wood stain


Next the top is separated and hinges are added and the corners are sanded and finished.

When all this is done you should have a box that looks something like this.

Plant Wood Rectangle Outdoor furniture Grass


To see other boxes click here.

PS

Making a tutorial with this many links and pictures is pretty exhausting. I hope it is of use to my fellow Lumber Jocks.
Al,
I do know how complicated and time consuming writing this kind of blog is… you have done an excellent job. I particularly like your technique and your pictures. All the little hints are great as well (upside down glue bottle, your glue center) I cut my excess off the splines with a dozuko saw. This works well too.
Ellen
 

Attachments

#168 ·
Making Indented Finger Lifts

How To Make An Indented Finger Lift

In short, you use an oscillating spindle sander set on an angle to sand away the center indent, and a spacer jig set over the locking guide to sand away the two smaller indents.

If you are just making one or two boxes, at the end of this tutorial I will make suggestions for how to do this same task much more simply if you don't want to make the jig, modify the table top, or buy a locking straight edge.

Rectangle Wood Material property Box Hardwood


Thanks to Maplerock aka Jerry for coming by the shop to help me with these pictures.

This year I have been using a three-part finger indent for my boxes. As requested, this is a how-to tutorial for how I make these lifts in my shop. Skip to the end if you want a scaled down version of this technique. When this process is finished, it looks like this.

Brown Wood Amber Gesture Wood stain


The Goal: We want to cut a centered finger lift in the front of the box. The process starts with an Oscillating Jet Table-Top spindle sander like this.

Like some of you, I bought a spindle sander some time back for another project. It has been just sitting around the shop with nothing much to do since. So once I came up with this design for my boxes it had a job, and we both were happy again.

Modifications: If you are just making one box, you could use the original top of the tool, but there is not much room to work. The same steps are used if you are working on the original tool's top.

Since I make a lot of boxes, I modified the tool. I added a bigger, half inch plywood top. On the back side of the top, it has a frame around the tool's original metal top and is fastened down securely with a tapped-in threaded knob. I also added a line drawn from the center of the spindle down the board.

Wood Floor Wood stain Flooring Hardwood


There is a removable cleat on the left hand side that comes in handy when the table is slanted. The next modification is a clamping straight edge. I would also recommend an accessory such as a wide jaw or added squaring attachment. (Pictured below) It helps to keep the clamping edge square to the line and will add accuracy.

Wood Finger Rectangle Material property Wood stain


Measuring For The First Cut: Now lets get to the actual work. Find the front-center of your box. Marking is more accurate than measuring. So, use a combination square to do that job. (We need to set the square's blade to the box's center anyway for the next step.)

Make a guess at the center of the box and hold the combination square on one side of the box like this. Mark the end of your blade.

Watch Hand Tableware Wood Finger


Now flip the combination square to the other side and mark the end of the blade. Like this.

Wood Watch Finger Wood stain Guitar


It is difficult to judge the center of a 12 inch box. It is easy to judge the center between two marks an inch or so apart. (This method works if your guess is long or short.) Move your blade to the center of the two marks (the center of the box) and draw a dark mark at the center. Be sure your blade is set at the center mark. Keep your blade locked down and use it for the next step.

Using the spindle center line as a base, and your combination square as a guide, set and lock the straight edge so the spindle will cut right at the center of your box-front.

Table Wood Wood stain Hand tool Hardwood


Making The First Indent: Slide your box up the guide being sure it is touching all along the guide and is square to the center line. Lightly touch the box to leave a small mark. Check to see if it aligns with the center mark you added to the box.

Brown Wood Amber Flooring Wood stain


If the spindle is not aligned with the mark, you can still make changes and sand away your mistake at this point. Now sand your center finger lift. A steeper angle on the sander will give you a shorter, deeper lift. A more shallow angle will give you a longer lift. There is no formula here, but bigger boxes generally look better with longer lifts. Don't sand so deeply that you go through the thickness of your box.

Hooray! The center cut is complete. You can stop here or you can add the two small indents at each side.

Cutting The Flanking Notches:

I use a simple jig to space the three notches evenly with no measuring. Look closely at this shot of the jig that lays over the guide.

Wood Hardwood Wood stain Varnish Plywood


The right-hand walnut spacer is 5/8 inches wide.
The light maple wood spacer is 1 1/4 or 10/8 inches wide.
The center piece is as wide as the guide.
So, the maple spacer is twice as wide as the walnut spacer.

How The Jig Works: We can use this jig to move the box into three positions. When the narrow spacer is between the guide and the spindle, the box is centered on the spindle. When the wide spacer is between the guide and the spindle, the box is moved 5/8 of an inch further from the guide. When we take the jig off the guide entirely, the box slides 5/8 of an inch toward the guide. There is no measuring and the three notches are in the right place every time.

Doing These Steps In Pictures:

Remove the spacing jig from the guide

Wood Guitar accessory Wood stain Musical instrument accessory Finger


Add a steeper angle to the table top, move the box over to the bear guide and slide it to the spindle. It just takes a slight touch here, and it will look like this.

Wood Finger Wood stain Flooring Hardwood


Now, put the thick side of the spacing jig over the guide and make sure the thick side is facing the spindle.

Wood Gesture Wood stain Flooring Varnish


Bring your box up to the spindle for another quick touch. It should look like this.

Wood Rectangle Wood stain Table Plank


As long as you don't move the guide fence, you can go back and re-sand any of your lifts and make them even or deeper by using the spacer jig.

Added Hints:

I use a 1" spindle with a 100 grit sleeve for sanding these. You may be happier with a larger or smaller spindle and a rougher or smoother grit. I find it is quicker to use the rougher grit and do just a bit of hand touch up when I am done.

Rolling pin Wood Finger Musical instrument accessory Table


A wide variety of shapes and sizes can be achieved by changing the angles and the depth of the notches. Have fun with that. I also sand the outside edges of the notches, the top lid edge above the lift, and the internal ridges of the lift so it feels good to the touch when you open the box.

Brown Rectangle Wood Wood stain Box


Even with the set-up time, I can create a three part finger lift for most boxes in about 5 minutes…certainly less time than it takes to explain how to do it in this forum.

A Simple Method: If you are just making a box or two I have a less elegant, but accurate way of doing this. I used this method while I was developing what I have shown above.

Draw a line on your sander table from the spindle center down to the front edge of the table. (No spindle sander? With some set up, you could use a sanding drum in a drill press to do this job as well.)

Use a combination square to set a locking or clamped straight edge as I described above, but tape a 5/8 piece of wood to the side of your guide before you set your guide in place.

Slant your table and cut your center indent.

Remove the tape and 5/8 strip and cut the new indent at a steeper angle.

Add a 1 1/4 inch spacer taped to the side of your guide. At the same angle as the last cut, sand out the other indent on the side of the center cut.

This method uses no jigs, no table modifications, and you don't have to have a clamping straight edge.

Rectangle Wood Hardwood Varnish Wood stain


Comments:

As always, thanks for looking and all comments and suggestions are appreciated. Keep boxing and keep posting.
 

Attachments

#169 ·
Making Indented Finger Lifts

How To Make An Indented Finger Lift

In short, you use an oscillating spindle sander set on an angle to sand away the center indent, and a spacer jig set over the locking guide to sand away the two smaller indents.

If you are just making one or two boxes, at the end of this tutorial I will make suggestions for how to do this same task much more simply if you don't want to make the jig, modify the table top, or buy a locking straight edge.

Rectangle Wood Material property Box Hardwood


Thanks to Maplerock aka Jerry for coming by the shop to help me with these pictures.

This year I have been using a three-part finger indent for my boxes. As requested, this is a how-to tutorial for how I make these lifts in my shop. Skip to the end if you want a scaled down version of this technique. When this process is finished, it looks like this.

Brown Wood Amber Gesture Wood stain


The Goal: We want to cut a centered finger lift in the front of the box. The process starts with an Oscillating Jet Table-Top spindle sander like this.

Like some of you, I bought a spindle sander some time back for another project. It has been just sitting around the shop with nothing much to do since. So once I came up with this design for my boxes it had a job, and we both were happy again.

Modifications: If you are just making one box, you could use the original top of the tool, but there is not much room to work. The same steps are used if you are working on the original tool's top.

Since I make a lot of boxes, I modified the tool. I added a bigger, half inch plywood top. On the back side of the top, it has a frame around the tool's original metal top and is fastened down securely with a tapped-in threaded knob. I also added a line drawn from the center of the spindle down the board.

Wood Floor Wood stain Flooring Hardwood


There is a removable cleat on the left hand side that comes in handy when the table is slanted. The next modification is a clamping straight edge. I would also recommend an accessory such as a wide jaw or added squaring attachment. (Pictured below) It helps to keep the clamping edge square to the line and will add accuracy.

Wood Finger Rectangle Material property Wood stain


Measuring For The First Cut: Now lets get to the actual work. Find the front-center of your box. Marking is more accurate than measuring. So, use a combination square to do that job. (We need to set the square's blade to the box's center anyway for the next step.)

Make a guess at the center of the box and hold the combination square on one side of the box like this. Mark the end of your blade.

Watch Hand Tableware Wood Finger


Now flip the combination square to the other side and mark the end of the blade. Like this.

Wood Watch Finger Wood stain Guitar


It is difficult to judge the center of a 12 inch box. It is easy to judge the center between two marks an inch or so apart. (This method works if your guess is long or short.) Move your blade to the center of the two marks (the center of the box) and draw a dark mark at the center. Be sure your blade is set at the center mark. Keep your blade locked down and use it for the next step.

Using the spindle center line as a base, and your combination square as a guide, set and lock the straight edge so the spindle will cut right at the center of your box-front.

Table Wood Wood stain Hand tool Hardwood


Making The First Indent: Slide your box up the guide being sure it is touching all along the guide and is square to the center line. Lightly touch the box to leave a small mark. Check to see if it aligns with the center mark you added to the box.

Brown Wood Amber Flooring Wood stain


If the spindle is not aligned with the mark, you can still make changes and sand away your mistake at this point. Now sand your center finger lift. A steeper angle on the sander will give you a shorter, deeper lift. A more shallow angle will give you a longer lift. There is no formula here, but bigger boxes generally look better with longer lifts. Don't sand so deeply that you go through the thickness of your box.

Hooray! The center cut is complete. You can stop here or you can add the two small indents at each side.

Cutting The Flanking Notches:

I use a simple jig to space the three notches evenly with no measuring. Look closely at this shot of the jig that lays over the guide.

Wood Hardwood Wood stain Varnish Plywood


The right-hand walnut spacer is 5/8 inches wide.
The light maple wood spacer is 1 1/4 or 10/8 inches wide.
The center piece is as wide as the guide.
So, the maple spacer is twice as wide as the walnut spacer.

How The Jig Works: We can use this jig to move the box into three positions. When the narrow spacer is between the guide and the spindle, the box is centered on the spindle. When the wide spacer is between the guide and the spindle, the box is moved 5/8 of an inch further from the guide. When we take the jig off the guide entirely, the box slides 5/8 of an inch toward the guide. There is no measuring and the three notches are in the right place every time.

Doing These Steps In Pictures:

Remove the spacing jig from the guide

Wood Guitar accessory Wood stain Musical instrument accessory Finger


Add a steeper angle to the table top, move the box over to the bear guide and slide it to the spindle. It just takes a slight touch here, and it will look like this.

Wood Finger Wood stain Flooring Hardwood


Now, put the thick side of the spacing jig over the guide and make sure the thick side is facing the spindle.

Wood Gesture Wood stain Flooring Varnish


Bring your box up to the spindle for another quick touch. It should look like this.

Wood Rectangle Wood stain Table Plank


As long as you don't move the guide fence, you can go back and re-sand any of your lifts and make them even or deeper by using the spacer jig.

Added Hints:

I use a 1" spindle with a 100 grit sleeve for sanding these. You may be happier with a larger or smaller spindle and a rougher or smoother grit. I find it is quicker to use the rougher grit and do just a bit of hand touch up when I am done.

Rolling pin Wood Finger Musical instrument accessory Table


A wide variety of shapes and sizes can be achieved by changing the angles and the depth of the notches. Have fun with that. I also sand the outside edges of the notches, the top lid edge above the lift, and the internal ridges of the lift so it feels good to the touch when you open the box.

Brown Rectangle Wood Wood stain Box


Even with the set-up time, I can create a three part finger lift for most boxes in about 5 minutes…certainly less time than it takes to explain how to do it in this forum.

A Simple Method: If you are just making a box or two I have a less elegant, but accurate way of doing this. I used this method while I was developing what I have shown above.

Draw a line on your sander table from the spindle center down to the front edge of the table. (No spindle sander? With some set up, you could use a sanding drum in a drill press to do this job as well.)

Use a combination square to set a locking or clamped straight edge as I described above, but tape a 5/8 piece of wood to the side of your guide before you set your guide in place.

Slant your table and cut your center indent.

Remove the tape and 5/8 strip and cut the new indent at a steeper angle.

Add a 1 1/4 inch spacer taped to the side of your guide. At the same angle as the last cut, sand out the other indent on the side of the center cut.

This method uses no jigs, no table modifications, and you don't have to have a clamping straight edge.

Rectangle Wood Hardwood Varnish Wood stain


Comments:

As always, thanks for looking and all comments and suggestions are appreciated. Keep boxing and keep posting.
fantastic jig. takes the sander to another level.
 

Attachments

#182 ·
Making Tea Box Dividers Of Venetian Blinds

How do you install a grid work inside a tea box so it looks like this?

Rectangle Wood Box Bag Cosmetics


Here is what the lift-out grill work looks like inside the tea box.

Wood Art Creative arts Triangle Table


This is what the lift-out grill work looks like outside of the box.

The small compartment to the left makes a chain pocket so the stop chain doesn't get tangled with the teabags.
.
.
Why use Venetian blinds for lift-out dividers?

By the time you plane, sand, and finish slats to make dividers inside boxes you have a lot of time and effort invested. Discovering that I could make my dividers out of recycled wooden Venetian blinds took most of the drudgery out of the process of adding dividers to my jewelry and tea boxes. Please don't use the plastic type of blinds. They are not stiff enough and are really ugly in a box.

A special thanks to Josh for helping with the pictures for this tutorial.
,

.

Overview: I will explain the general process in the two languages all Lumber Jocks speak: words and pictures.

First, we'll see how to build a box the right size to hold teabags, and then we'll see how to make the grid.

Hand Light Wood Finger Wood stain


.
.

The Process in Words

Build a box the right size for teabags.

Remove all the strings and metal from a WOODEN Venetian blind.

Trim the slats to fit inside the box. Two for the length and several for the width.

Use the wooden teabags to space the width pieces.

Use a compass to space the length pieces.

Cut all the pieces half way through with a 1/8 inch blade.

Put some aluminium foil in the bottom of the box.

Dry fit the grid inside the box.

While the grid is in the box, remove just one piece.

Apply glue with a syringe into the half-lap slot and glue the grid together.

Wipe away excess glue.

Let the glue set while grid is in the box.
.
.
The Process in Pictures
.
.
First you need to make the tea box the right size. This method keeps measurements to a minimum. That means there is far less to go wrong.

Wood Rectangle Hardwood Wood stain Font


The key to making this system work is making some teablocks and having some scrap pieces of Venetian blind. Here I have organized seven blocks and some blind scraps in their own small cherry box.

Rectangle Packing materials Ingredient Wood Packaging and labeling


Make 6 or 7 wooden blocks as wide as a teabag and a little taller. I am going to call these "teablocks" in the rest of this tutorial. You are going to use these for the layout of both your box and your grid work.

Wood Rectangle Flooring Floor Table


Here you can see the layout for the box. Before you do anything plane down a board to about 5/8 of an inch. Add the bottom groove for the bottom board of the box.

Cut two small slices from the actual board you are going to use and place them on the outside of the layout. Then place some scrap 1/8 inch pieces of Venetian blind between the tea blocks. Three of these scrap pieces between gives plenty of room for teabags to slide into the compartments easily. Add a small scrap to use to space out for the chain pocket. You can see that spacing on the left.

If you squeeze all these parts together you can measure from end to end and it should give you the exact size for the boards you need to make the front and back of the box. Don't fight this. If it is close, round up to the nearest 1/4 inch. You can always make your chain pocket a little larger. If you make your tea box too small and the teabags don't fit…then you have a problem. Round up.

Brown Rectangle Wood Luggage and bags Bag


You can make the depth of the box any size, but if it is less than 6 inches it tends to get tippy when you open the lid. Too much over 8 inches wide and it is getting to be a really big teabox.
.
.

Summary so far:

We have the the width and depth measurement for our box. So 2 times the width plus 2 times the length makes the length of the board we need. Lets say it is 8 1/2 inches long and 7 inches wide. We would need a board (2×8 1/2 + 2×7=17+14=31) 31 inches long. Add 1 inch for the cross cuts you will make on the board and you now need a board 32 inches long. If your board is slightly less, make your box a bit more narrow. If your board is much too short, start over with the layout and take out one or two teablocks.
To figure out the height of the box, set a teablock on the top of your groove for the bottom board and measure where you want to put the groove for the top of the box. Remember: You will need some extra room inside the box. The inside front of the hinged box will hang up on the top of the teabags as the lid closes if you don't have that extra 3/4 of an inch or so of room. When you cut the lid off this box, use a slat plus at least a quarter of an inch to mark a line for your saw cut to slice the top off.

So you have a box the right size, how about the lift out dividers? This system makes the dividers into a unit, but the whole unit can be lifted out of the box if the buyer wants to re-purpose the box.

Hand Wood Tool Eyewear Bumper


Cut away any slots or notches in the blinds so you don't accidentally put them in your work.

Wood Rectangle Wood stain Hardwood Kitchen appliance


Re-assemble the teablocks and spacers inside the box.

Brown Wood Amber Publication Hardwood


Make sure your slat is squared. Hold the slat across the inside of the box and mark the end.

Wood Rectangle Wood stain Hardwood Varnish


Fit the slat into the box. Don't make it so tight that you can't get the grid work in and out of the box.

Watch Wood Finger Musical instrument Human leg


Here is a short cut. Make the second slat the same size by putting the ends even, laying it on top of the slat you want to cut, and then bumping the top board on the blade of the chop saw while the bottom board slides under. Without removing the top board, cut the bottom board. If you take the top board off, you are going to move something.

Wood Finger Wood stain Hardwood Rectangle


Okay, we now have the two long slats cut to the correct length. Now, put a small pencil mark on the slat where it crosses the middle of the three spacers between the teablocks. This is to mark where you want the dividers to cross inside the box.

Hand Wood Wood stain Finger Tableware


Mark and cut the shorter cross pieces to length. Don't fit them too tightly.

Wood Finger Thumb Wood stain Hardwood


Tape your two long pieces together. Tape all of your short pieces together making sure all the ends are even.

Hand Wood Sleeve Finger Gesture


A compass is a quick and easy way to be sure your compartments inside the box are all the same size. On the top slat of your taped up short pieces, just step off three equal steps and adjust the compass until they are equal. When you have it right just bear down on your points and make some small dents that will show you where to cut your half slots.

Hand Wood Finger Bumper Gas


Since I know my slats are 2 inches wide, I keep a small spacer in my teablock kit. The spacer is one inch wide plus a 32nd. With the saw turned off and unplugged, bring your spacer next to the saw blade and carefully use your fingers to tell you when the top of the spacer is even with the top of the blade.

Hand Wood Gesture Tool Flooring


Set your miter fence at 90 degrees to the blade. Being very careful to keep your fingers well away from the blade, cut the slots at your compass indents in the short pieces. Don't drag the slats back through your blade. Make the cut and lift your work away before you pull it back. With a single pass you will get just the right width and will have a nice tight fit. Hint: You want to cut very slightly past the halfway point of your slat width. This extra space makes sure your pieces will all fit flat on the bottom of your box and it gives the extra glue a place to go.

Wood Flooring Floor Rectangle Wood stain


Now use this same technique to make the half lap cuts in your longer slats. This time cutting where you marked the lines using the re-assembled teablocks.

I didn't picture this step, but usually I put a piece of aluminium foil in the bottom of the box to protect the finish from glue squeeze out. The foil doesn't have to fit tightly around the whole bottom, it only has to be under the places where the slats cross.

Musical instrument Wood Rectangle Tool Hardwood


Dry fit your slats inside your box. Make sure they don't fit too tightly. Hint: I find it is easier to first put the long slats inside with the slots facing upward. The I can fit the short slats in quickly since I am just aligning two slots.

Hand Wood Finger Microphone Thumb


You can use a glue bottle, but I have found this is a great time to use a glue syringe. It allows you to put the glue where you want it and not make a complete mess of it.

Watch Wood Rectangle Wood stain Cuisine


This is another reason to put the short pieces in with the slots down. You can remove just one slat from your dry fit and leave the rest of the slats in place while you apply the glue.

Finger Wood Paint Flooring Wood stain


I use a thick glue so it doesn't run. Apply just a little glue on both sides of the slot. It really doesn't take much.

Hand Wood Finger Rectangle Wood stain


When you re-insert the short piece, be sure you push it down all the way so it touches the bottom.

Hand Wood Finger Wood stain Varnish


No matter how careful you are, you are going to have some squeeze out with the glue process. I use a small bladed screwdriver and a paper towel to remove the glue.
Hand Wood Finger Wood stain Hardwood


Since slats are prefinished, you are bound to have some slight chip out with your cuts even with the best and sharpest blades. Little things make a difference in your work. The big box store sell furniture markers that are made much like a magic marker or felt tipped pen. They come an an assortment of colors. It is easy to match these to your slat color and just take a minute or two to color any chips.

Wood Wood stain Flooring Hardwood Varnish


Probably no one will care but me, still I take a little time to color the ends of the slats and apply one quick coat of finish to them when I am working on the next box.

Hand Light Wood Finger Wood stain


Leave the grid work inside the box until the glue sets. That way you can be sure it will fit the box.

Ta-Da! You now have the right sized box and a grid that separates the tea box into several neat compartments. Once it is glued, assembled, and set inside the box it is surprisingly strong and durable though it is made of fragile material.
 

Attachments

#183 ·
Making Tea Box Dividers Of Venetian Blinds

How do you install a grid work inside a tea box so it looks like this?

Rectangle Wood Box Bag Cosmetics


Here is what the lift-out grill work looks like inside the tea box.

Wood Art Creative arts Triangle Table


This is what the lift-out grill work looks like outside of the box.

The small compartment to the left makes a chain pocket so the stop chain doesn't get tangled with the teabags.
.
.
Why use Venetian blinds for lift-out dividers?

By the time you plane, sand, and finish slats to make dividers inside boxes you have a lot of time and effort invested. Discovering that I could make my dividers out of recycled wooden Venetian blinds took most of the drudgery out of the process of adding dividers to my jewelry and tea boxes. Please don't use the plastic type of blinds. They are not stiff enough and are really ugly in a box.

A special thanks to Josh for helping with the pictures for this tutorial.
,

.

Overview: I will explain the general process in the two languages all Lumber Jocks speak: words and pictures.

First, we'll see how to build a box the right size to hold teabags, and then we'll see how to make the grid.

Hand Light Wood Finger Wood stain


.
.

The Process in Words

Build a box the right size for teabags.

Remove all the strings and metal from a WOODEN Venetian blind.

Trim the slats to fit inside the box. Two for the length and several for the width.

Use the wooden teabags to space the width pieces.

Use a compass to space the length pieces.

Cut all the pieces half way through with a 1/8 inch blade.

Put some aluminium foil in the bottom of the box.

Dry fit the grid inside the box.

While the grid is in the box, remove just one piece.

Apply glue with a syringe into the half-lap slot and glue the grid together.

Wipe away excess glue.

Let the glue set while grid is in the box.
.
.
The Process in Pictures
.
.
First you need to make the tea box the right size. This method keeps measurements to a minimum. That means there is far less to go wrong.

Wood Rectangle Hardwood Wood stain Font


The key to making this system work is making some teablocks and having some scrap pieces of Venetian blind. Here I have organized seven blocks and some blind scraps in their own small cherry box.

Rectangle Packing materials Ingredient Wood Packaging and labeling


Make 6 or 7 wooden blocks as wide as a teabag and a little taller. I am going to call these "teablocks" in the rest of this tutorial. You are going to use these for the layout of both your box and your grid work.

Wood Rectangle Flooring Floor Table


Here you can see the layout for the box. Before you do anything plane down a board to about 5/8 of an inch. Add the bottom groove for the bottom board of the box.

Cut two small slices from the actual board you are going to use and place them on the outside of the layout. Then place some scrap 1/8 inch pieces of Venetian blind between the tea blocks. Three of these scrap pieces between gives plenty of room for teabags to slide into the compartments easily. Add a small scrap to use to space out for the chain pocket. You can see that spacing on the left.

If you squeeze all these parts together you can measure from end to end and it should give you the exact size for the boards you need to make the front and back of the box. Don't fight this. If it is close, round up to the nearest 1/4 inch. You can always make your chain pocket a little larger. If you make your tea box too small and the teabags don't fit…then you have a problem. Round up.

Brown Rectangle Wood Luggage and bags Bag


You can make the depth of the box any size, but if it is less than 6 inches it tends to get tippy when you open the lid. Too much over 8 inches wide and it is getting to be a really big teabox.
.
.

Summary so far:

We have the the width and depth measurement for our box. So 2 times the width plus 2 times the length makes the length of the board we need. Lets say it is 8 1/2 inches long and 7 inches wide. We would need a board (2×8 1/2 + 2×7=17+14=31) 31 inches long. Add 1 inch for the cross cuts you will make on the board and you now need a board 32 inches long. If your board is slightly less, make your box a bit more narrow. If your board is much too short, start over with the layout and take out one or two teablocks.
To figure out the height of the box, set a teablock on the top of your groove for the bottom board and measure where you want to put the groove for the top of the box. Remember: You will need some extra room inside the box. The inside front of the hinged box will hang up on the top of the teabags as the lid closes if you don't have that extra 3/4 of an inch or so of room. When you cut the lid off this box, use a slat plus at least a quarter of an inch to mark a line for your saw cut to slice the top off.

So you have a box the right size, how about the lift out dividers? This system makes the dividers into a unit, but the whole unit can be lifted out of the box if the buyer wants to re-purpose the box.

Hand Wood Tool Eyewear Bumper


Cut away any slots or notches in the blinds so you don't accidentally put them in your work.

Wood Rectangle Wood stain Hardwood Kitchen appliance


Re-assemble the teablocks and spacers inside the box.

Brown Wood Amber Publication Hardwood


Make sure your slat is squared. Hold the slat across the inside of the box and mark the end.

Wood Rectangle Wood stain Hardwood Varnish


Fit the slat into the box. Don't make it so tight that you can't get the grid work in and out of the box.

Watch Wood Finger Musical instrument Human leg


Here is a short cut. Make the second slat the same size by putting the ends even, laying it on top of the slat you want to cut, and then bumping the top board on the blade of the chop saw while the bottom board slides under. Without removing the top board, cut the bottom board. If you take the top board off, you are going to move something.

Wood Finger Wood stain Hardwood Rectangle


Okay, we now have the two long slats cut to the correct length. Now, put a small pencil mark on the slat where it crosses the middle of the three spacers between the teablocks. This is to mark where you want the dividers to cross inside the box.

Hand Wood Wood stain Finger Tableware


Mark and cut the shorter cross pieces to length. Don't fit them too tightly.

Wood Finger Thumb Wood stain Hardwood


Tape your two long pieces together. Tape all of your short pieces together making sure all the ends are even.

Hand Wood Sleeve Finger Gesture


A compass is a quick and easy way to be sure your compartments inside the box are all the same size. On the top slat of your taped up short pieces, just step off three equal steps and adjust the compass until they are equal. When you have it right just bear down on your points and make some small dents that will show you where to cut your half slots.

Hand Wood Finger Bumper Gas


Since I know my slats are 2 inches wide, I keep a small spacer in my teablock kit. The spacer is one inch wide plus a 32nd. With the saw turned off and unplugged, bring your spacer next to the saw blade and carefully use your fingers to tell you when the top of the spacer is even with the top of the blade.

Hand Wood Gesture Tool Flooring


Set your miter fence at 90 degrees to the blade. Being very careful to keep your fingers well away from the blade, cut the slots at your compass indents in the short pieces. Don't drag the slats back through your blade. Make the cut and lift your work away before you pull it back. With a single pass you will get just the right width and will have a nice tight fit. Hint: You want to cut very slightly past the halfway point of your slat width. This extra space makes sure your pieces will all fit flat on the bottom of your box and it gives the extra glue a place to go.

Wood Flooring Floor Rectangle Wood stain


Now use this same technique to make the half lap cuts in your longer slats. This time cutting where you marked the lines using the re-assembled teablocks.

I didn't picture this step, but usually I put a piece of aluminium foil in the bottom of the box to protect the finish from glue squeeze out. The foil doesn't have to fit tightly around the whole bottom, it only has to be under the places where the slats cross.

Musical instrument Wood Rectangle Tool Hardwood


Dry fit your slats inside your box. Make sure they don't fit too tightly. Hint: I find it is easier to first put the long slats inside with the slots facing upward. The I can fit the short slats in quickly since I am just aligning two slots.

Hand Wood Finger Microphone Thumb


You can use a glue bottle, but I have found this is a great time to use a glue syringe. It allows you to put the glue where you want it and not make a complete mess of it.

Watch Wood Rectangle Wood stain Cuisine


This is another reason to put the short pieces in with the slots down. You can remove just one slat from your dry fit and leave the rest of the slats in place while you apply the glue.

Finger Wood Paint Flooring Wood stain


I use a thick glue so it doesn't run. Apply just a little glue on both sides of the slot. It really doesn't take much.

Hand Wood Finger Rectangle Wood stain


When you re-insert the short piece, be sure you push it down all the way so it touches the bottom.

Hand Wood Finger Wood stain Varnish


No matter how careful you are, you are going to have some squeeze out with the glue process. I use a small bladed screwdriver and a paper towel to remove the glue.
Hand Wood Finger Wood stain Hardwood


Since slats are prefinished, you are bound to have some slight chip out with your cuts even with the best and sharpest blades. Little things make a difference in your work. The big box store sell furniture markers that are made much like a magic marker or felt tipped pen. They come an an assortment of colors. It is easy to match these to your slat color and just take a minute or two to color any chips.

Wood Wood stain Flooring Hardwood Varnish


Probably no one will care but me, still I take a little time to color the ends of the slats and apply one quick coat of finish to them when I am working on the next box.

Hand Light Wood Finger Wood stain


Leave the grid work inside the box until the glue sets. That way you can be sure it will fit the box.

Ta-Da! You now have the right sized box and a grid that separates the tea box into several neat compartments. Once it is glued, assembled, and set inside the box it is surprisingly strong and durable though it is made of fragile material.
Another gem in a series of gems. Thanks so much Boxguy, your blogs are very helpful, and you are a great contributor on this site. When I first got here you helped me out a lot. Your work is inspiring.
 

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