Well my shop is now a wreck, my eyes are full of dust and I had a blast. LOL.
Lets start with the box and grinder. As you can see I drew in the lines on the handle to match up to the box.
In the next pictures you will see the grinding process. I thought long and hard about making a video and decided that there wasn’t really a way for me to do it at this time. Maybe I will revisit the idea in the future.
I start at my line and gentle pull into the center. I then go to the next line and pull to the center again, creating a hollow. I try to just take a little at a time. I must also mention that you need to keep in mind the position of the hinge pins and the dado for the bottom. Going to deep at either place will result in a pretty box for the shop. LOL. When I drew my layout onto the box, I put the hinge pins in the center of the hollows and had to redraw them before I started grinding. The more “beef” you can leave around the pins, the stronger the lid will be. Well here are the pictures you have been waiting for. I hope they help show the process I use to make this type of box. I know a lot of others have perfected this style box, like Andy and Greg, and I am still working to reach their level, but I learn with each box and have fun doing it. I hope this helps you to give it a try.
The last picture is a reminder to use your common sense. Grinding throws up a lot of dust and is loud. I use, safety glasses and will be investing in goggles soon because of the dust build up in my eyes. I would also recommend a respirator over a dust mask but use something. You don’t want to be breathing that stuff. Finally don’t forget the ear protection. The grinders are loud and dangerous and should be respected in every aspect of their use. It is also not recommended to take off the guard. You can see in the picture that I have, but beware, it does make this more dangerous than it all ready is.
Finally as you will see in my pictures, make sure the box is secured. The grinder can and will sling the box across the shop if it is not. At first I clamped it down, but having to move it around in all kinds of different positions, it is not always possible to clamp the box to the work surface. A vise may work but not having one, I found a different way. I use blocks that are screwed to a piece of plywood that is clamped to my table saw. I can quickly unscrew the blocks and move them as I need to.
If I left anything out, please ask and I will try to answer. Or if you can think of a different or better way to make any of these steps safer or easier my ears are open.
Next will be lots and lots of sanding. The not so fun part. LOL. I have found a “zen” place I go in my mind when sanding and it has become like a meditative exercise. It helps when there is hours of sanding to do, but more on that next episode.
As always, thanks for joining me on the journey.
See ya next time
-- JoeyG ~~~ http://www.facebook.com/JHGWoodWorks