So I have started on my box project! I had originally wanted to start with a similar design as Douglas’s box (see his project), however I wanted something even easier to start back into woodworking with. So I chose this simple design, featuring a flush lid that is opened by a bit of lever action when an end is pressed down.
Of course, all good things start with a plan… Since I no longer had access to any cutlist software, and since this is a simple 6-sided box, I tried a few layouts on paper first. What I realized is that since I could resaw the 3/4” stock into 1/4” boards, I could make better use of my material. And I further noticed that since the sides of the box were so short, I could make an extra box with only a bit of extra wood, thereby reducing my waste!
For this, I needed 1/4 inch stock, and I had a choice: either plane down 3/4 stock and waste most of it, or use it as an excuse to buy another tool! So the choice was obvious, and I am now the owner of a bandsaw (see my review).
I started by jointing one face and then one end.
I then planed the other face and the other end.
I then moved to my bandsaw and split the 3/4” board into two almost perfect halves. The only trouble I had here is when I got 3/4 way through the board, the lacewood I was splitting was pinching my blade. Since my bandsaw is an anemic 3Amp saw, the blade slowed to a stop. Since I had calibrated the blade to the exact center, I just stopped the machine, pulled my board out, turned the machine back on, and fed the wood back, the other end first. Perfect cut!
I then used the planer again to smoothen the exposed rough side, and slowly worked my way down to 1/4 inch boards. I passed both boards through the planer every time I lowered the blade, to ensure both pieces were exactly the same thickness.
And that’s where I called it a day, since the baby was now asking to be fed, and she’s more important than playing with my tools… ;)
-- Dekker - http://www.WoodworkDetails.com/