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Blog series by Jon3 updated 02-23-2009 12:16 AM 6 parts 4869 reads 17 comments total

Part 1: In The Beginning, There was Mahogany!

02-22-2009 11:25 PM by Jon3 | 1 comment »

In the beginning, there was a big 8/4 mahogany board. And it was good. I cut a chunk offa the end, and surfaced it. Into the resaw blade it went. Then some sides and ends appeared. There was no need to do any advanced bookmatching, the grain is practically parallel, and the box will be tailed, not mitered.

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Part 2: Pins first. A Klausian Journey.

02-22-2009 11:36 PM by Jon3 | 2 comments »

Let there be layout marks! Here come the pins. I am a Klausian dovetailer. Yup, those were merely eyeballed. Out comes the Lie-Nielsen chisels from my fabulous wife (given to me when she was a Fiance). First we chop lightly just shy of the line. And relieve the light cut. This means when you use your strike line later, the shape of the chisel won’t push you back into the workpiece. Path of least resistance now works in your favor. And the other side ...

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Part 3: Gappy like your gran pappy's teeth after 80 years of sweets.

02-22-2009 11:44 PM by Jon3 | 3 comments »

Of course, some of the dovetails looked straight out of a book. Some did not. Most were average. But there is hope! Tails are so very fixable. First, you cut a nice clean kerf with your dovetail saw. This makes the gap a uniform size. You shave off some nice thin and thick slivers and prepare some wedges. Slather glue liberally. I’m talking Democrat with a bailout plan style of liberal. Push/jam/pound wedges in (but don’t break em.) Oh...

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Part 4: Hardware, the next hurdle.

02-23-2009 12:03 AM by Jon3 | 1 comment »

Looking good so far. Now its time to mangle the pretty box up with hardware. I used a jig and routed out the quadrant hinge form. Which fit nicely. Only to provide me a box with a 3/16 offset the first time around. I assumed I messed up the jig, so I planed the top and bottom flat again, and re-read the manual before attacking some scrap wood. 3/16th again. A few emails back to the manufacturer, and I got a new one. (Beall, best service in the biz!) Now, the next ro...

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Part 5: The mistake train is leaving the station. All aboard!

02-23-2009 12:09 AM by Jon3 | 1 comment »

Rather than fiddle with the hinges, my Lie-Nielsen 4.5 came out, and I just shaved to suit. This kind of thing is where the power of hand tools really has no equal in the power tool world. What would you do without a hand tool here. Jam the whole box up against a belt sander? Notice in this real closeup photo you can also see my biggest dovetail fix. Had to get out my biggest kerf saw to get that giant gap filled. I noticed that from the back, with the hinges in place, this gap ...

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Part 6: Finishing is truly the final frontier.

02-23-2009 12:16 AM by Jon3 | 9 comments »

I’m always wary of finishing. I really don’t like it, as I often feel it is such a voodoo black art. And often I think its overdone. (c.f. people with posts that include ‘then I put on 293 coats of french polish, blah blah blah.) I apologize in advance for the lack of in-progress photos at this point. With finish on my hands and latex gloves on, I was in no position to be touching my nice camera. I used my leftover stock and prepared some various finishes. I tried...

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