I lay awake desperately for two hours trying to figure out how I was to cut four sides and a top from this striped cross.
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In the end I gave up and went to sleep.
My new planer arrived bright and early. My old one had died inexplicably. Damn I thought this is getting me away from the project. I dutifully put it together, tried it out and tidied away the old one all without much enthusiasm. Another trip to the re-cycle centre (used to be called the dump, now re-cycle Nazis quiz you as to whether you’ve sorted your trash). Tomorrow of course. Its only open Thursday to Sunday but I digress. In the end the shop looked almost normal and I glanced the stripey cross once more.
It was sitting on a scrap of 12mm MDF. You can saw a 3mm slot in a lump of MDF easily, not so a delicate little flower like the one sitting on top of it. If I could make the cross ‘one with the MDF’ I would have solved the problem. Old fashioned filament light bulb goes on in head! Cut the MDF to the outside size of the cross and route a cross shaped groove in it. Vioila! (the holes are incidental, an artifact of previous use of the MDF)
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The cross fits snugly in.
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First thing to do is route the lipping rebate in the sides
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Then cut the sides to length. Zero clearence slab of MDF on the tablesaw
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Fence distance set to the height of the side + 2mm (for box separation cut). Set blade height to 3mm so as to definitely cut through the box material and cut through all four sides
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Peel out the box sides
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Each side looks like this at the moment
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That may look a bit ragged but remember the piece is only 22mm x 20mm x 2mm.
I took the stumpy cross out of the jig and double sided taped it back in. Once I start cutting the stumps off there will be nothing left to hold it in there!
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Then reset the saw fence to cut the stumps off
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and sawed them off.
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Removed the top piece carefully, with a knife and cleaned off the double sided tape. Here the pieces are
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They will need to be edged with Ebony next and assembled. Thats for another blog though
Be seeing you
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com

















19 comments so far
Crushgroovin
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234 posts in 1121 days
#1 posted 937 days ago
Another Amazing Box from the Master Brit! What wood did you use? Looks like purpleheart, yellowheart, padauk, maple, and cherry??
-- I wouldn't be so arrogant if you weren't such a moron!
WoodshopJoe
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99 posts in 1457 days
#2 posted 937 days ago
I know how it is to ponder something as simple as cutting wood. I find your box making methodolgy very interesting and will have to make a go of it very soon. Thanks for sharing, I do enjoy reading your blog posts.
-- Joe Truehart - The Craftsmans Woodshop
shipwright
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3479 posts in 995 days
#3 posted 937 days ago
Cool Martyn. Re: “just because I hope I can” comment in segment # one, is it any fun if you know you can?
PS: You do know that you may be starting a “challenge of diminishing returns” don’t you. Which man will be able in the end to claim “Mine’s smaller than yours”?
-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fiberglass trees. http://prmdesigns.com/
Jamie Speirs
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3720 posts in 1053 days
#4 posted 937 days ago
Wow!
This is one nice project.
I’m impatient. :) Nearly as good as waiting 4 Santa. :)
Jamie
-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe
BritBoxmaker
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4054 posts in 1233 days
#5 posted 937 days ago
Crushgroovin’, thanks and the wood types are in part one of the blog.
Joe, thank you. I sometime wonder if I make it seem too simple. Once you get the trick though its easy.
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com
Sheila Landry (scrollgirl)
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6061 posts in 1117 days
#6 posted 937 days ago
Cool. Clean. Logical. I love the way you think things through so thoroughly when doing a project such as this. It looks so easy because you do it right.
Great project, Martyn. And wonderful lesson.
It is simply beautiful. I can’t wait to see the next step.
Thanks. :) Sheila
-- Contributing Editor, Creative Woodworks and Crafts, Sheila Landry Designs http://www.sheilalandrydesigns.com "Knowledge is Power"
SPalm
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4174 posts in 2079 days
#7 posted 937 days ago
You’re doing good. My that is small.
I hate those nights, laying awake, thinking. But then again, I love ‘em. It is what keeps me (and I believe you) going. Finding balance is what is needed.
Steve
-- -- I'm no rocket surgeon
Cozmo35
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2141 posts in 1233 days
#8 posted 937 days ago
Martyn, Each day you leave the shop, count your finger to make sure they are all still there! WOW! tiny pieces. If anyone can do it, it’s you!
-- If you don't work, you don't eat!.....Garland, TX
moshel
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845 posts in 1881 days
#9 posted 937 days ago
just leave it on the workbench for the night and the elves will put it together!
-- The woods are lovely, dark and deep, but I have promises to keep...
Div
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1653 posts in 1137 days
#10 posted 937 days ago
What a clever solution! I am impressed my man. Many times, my moments of brilliance (relatively speaking!) happens in the shower….!
-- Div @ the bottom end of Africa. "A woodworker's sharpest tool should be his mind."
Dennisgrosen
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10851 posts in 1312 days
#11 posted 937 days ago
DOOOOH! there I got kicked of the truck in the roadcurve a ½ mile back
but I take a hike and return to the next installment Proffessor
I like the way you used the Mdf to make it safer to cut
take care
Dennis
DragonLady
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298 posts in 1204 days
#12 posted 937 days ago
genius!
-- A woman's work is never done-but power tools help!
BertFlores58
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1552 posts in 1119 days
#13 posted 937 days ago
Brilliant and simple… But needs a lot of practice specially in the accuracy part.. Thanks Martyn for posting.
-- Bert
TopamaxSurvivor
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13179 posts in 1873 days
#14 posted 937 days ago
That is a good pic Autumn, love it! Excellant explanation of how it works and how Martyn solved his problem.
-- "some old things are lovely, warm still with life ... of the forgotten men who made them." - D.H. Lawrence
patron
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12168 posts in 1538 days
#15 posted 937 days ago
excellent solution martyn
reminds me about a story
i read about somewhere
the germans made the worlds smallest roller bearing
and were bragging about it to the world
in the hopes
of selling the technology
needed an electron microscope to see it
the japanese asked to get a look at it
the germans sent it to them
the japanese sent it back
about a month later
well the germans asked what they thought about it
“oh it is nice
but we don’t need your help”
in side the inner race hole
they had made one smaller
-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle
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