Starting to cut all the pattern pieces today. This is the pattern
Shown in plan and end elevation.
- Just a side note. If anyone is thinking of making one of these please could you wait until I have finished and posted mine. This is my design and it is a live blog of a project, in real time. I have been beaten to the punch by over-enthusiastic people before. Its not big and its not clever.
Now from the plan you can see that there are a number of small pieces here. The pattern is a repeat of one 45° triangular segment (as seen from the top), mirrored and repeated around the box. The upshot of this is that, apart from the central square, you need 8 of each piece. The white strips are English Sycamore, 6 mm x 3 mm. Also from the pattern you can see that each piece (going inward) is 12 mm shorter than the last. This allows for a trick whereby you only need to set up for cut length once. I’ll explain.
First I took a piece of 18 mm MDF. Planed and drum sanded it until it was exactly 12 mm thick ( I don’t trust the dimensions of off the shelf products). So
I cut 5×50 mm sections off it, so
Stood on end these can be used as fairly accurate 12 mm spacers.
Yes I know this is MDF and moisture content in the air will make it vary in thickness. That’s why I make and use these spacers on the same day and in the same conditions throughout).
Setting up my cross-cut jig (US – sled) for the longest piece length plus a couple of mm for clean up on the belt sander (see part one of the blog)
and putting 8 x strips in at a time
I cut the first strips. To cut the next shortest just add in one spacer
and so on. Please no belly aching about safety here. My hold down (which you will obviously need for the actual cut) for the strips is not shown for clarity of the point, about measurement, being made.
The same trick can be used for cutting the mitres on a mitre jig. Hold down also used here but not shown for clarity.
To give you an indication of just how ‘live’ this blog is you will see one long strip used in the last four images. This is because I’m writing these instructions shortly before actually doing the above described cutting. I know it will work I’ve done it this way before. In the next part of the blog I will show you the results of this and precision sizing using the belt sander.
Be seeing you
-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging. http://www.theartofboxes.com