Before starting this project, I want to ensure that I am fully prepared.
-am I familiar with all the different techniques to build the chest?
-what lumber do I need – which rough thicknesses and approximate number of board feet?
-what tools do I need?
As both a blanket chest and a piece of Greene and Greene furniture there are a variety of familiar and new woodworking techniques. These include:
-creating large panels by glueing up multiple boards
-creating a template for the finger joints
-using a jigsaw and then the template and flush trim bit to cut out the finger joints
-creating a variety of mortises for the ebony plugs
-creating and inserting all the ebony plugs
-making breadboard ends
-cutting and inserting the splines in the breadboard ends
-cutting and fitting the finger joints in the base
-finishing the chest
With all the resources I have for this project – the article in FWW, Marc’s videos for his chest, Darrell’s two books and William Ng’s videos I feel very confident that I have full instructions available for every technique required by the project.
For the lumber, the article did not include a formal cutlist. However the excellent diagram of the chest with all the dimensions allowed me to figure out how many board feet of 4/4 and 5/4 mahogany I needed. It was quite handy that my lumber source (KJP Hardwoods in Ottawa) did carry 5/4 stock as the top is 7/8” in thickness, the breadboard ends 1” in thickness and the base is 1” in thickness. I spent about $350 on the wood but I did overbuy and the mahogany at KJP was finished on 2 sides instead of being fully rough stock. I will also need to buy a 4’ x 4’ sheet of mahogany veneered plywood which will cost about $50. I also bought two pieces of ebony for $25.
My interest in tools required for the project wasn’t necessarily the big power tools as I have all the main ones to build the project. Rather I needed to ensure I had all the router bits and square hole punches necessary. After going through the plans I determined I needed 7 different router bits and 3 square hole punches. I had a couple of the router bits but ended up needing to buy a few along with three square hole punches. Lee Valley was happy to see me that day as I needed about $300 worth of stuff for this project.