This past week has been less productive than I would have liked. I’ve been struggling with a flue, thus operating at less than full capacity.
I worked in the shop last Wednesday, and took some pictures showing the installation of the splines in the spline slots shown in my previous episode of Making a Small Wooden Box. Unfortunately, my photo card was corrupted, so I lost all of those pictures.
Today, I will show you the continuation of making the lid and a start on one of the trays.
David has done a great job of showing veneering, so I don’t plan to go into any details on that here. This picture shows my lid panel ‘sandwich’ being glued up in my manual vacuum press. If you look very closely, you will see two cauls that make up the ‘bread’ of the sandwich, in between which is a layer of veneer, 3mm MDF and another layer of veneer. I left the sandwich in the press overnight.
Now I move on to the tray components. I plan to install fixed dividers in the bottom layer of the box interior. The dividers will serve as the shelf to hold two smaller trays in the top layer. I’ve chosen American Maple with a slight ‘bird’s eye’ affect. The trays will be lined with velvet and one or two compartments will feature ring holders. (Pictures of these in a few more episodes.)
Below are the tray-sides cut ready for additional milling. The saw blade has left some burns, but these will be removed during sanding.
The next two close-ups show one of the ways I use the Grrr-Ripper. I commented in Dick's blog about this tool that I find invaluable for milling small box pieces. The first picture shows the tray side being passed by a round-over bit on my router table and the second shows me cutting a rebate for the tray bottom on the tablesaw. I can’t think of a safer way to do this. You might note that the piece is ‘trapped’ between the fence of the router table and the bottom ‘stabilizer plate’ of the Gripper. It can’t go anywhere. Also, the side of the gripper is registered against the Router Table Fence, not the work-piece. This prevents ‘snipe’ from occurring which is the bane of milling small pieces on the Router Table.
The picture below shows the veneered panel inserted into the lid frame and the tray being glued up. (Please excuse the focus.)
I tend to pre-finish my boxes with Pure Tung Oil as I progress. I find this much easier than trying to reach into awkward corners and contending with a flapping hinged lid. I need to take care that I don’t apply any oil to surfaces that will be glued.
Below are two more pictures of the box. Hinges will not be applied until the last stage of making this box.
Add another 12 hours of shop time.
I know this is a fairly slow pace, but remember, each step is only performed once or a few times. This is not production run stuff, so one has to carefully think through each step, measure twice and cut once. The old adage, ‘haste makes waste’ is very applicable to woodworking, and sometimes a mistake means starting all over because of stock limitations, etc. For example, I have no more of the primary wood used in the box. Mess up now, and it would force me to start all over with a different wood.
-- CanuckDon "I just love small wooden boxes!" http://www.dpb-photos.com/