Updated 1/15/12 We now have our box assembled and glued up. Depending on the temperature, let it dry for a couple of hours, or overnight to be safe.Take the tape off and clean up any dried glue. This is a good time to smooth up the bottom to get rid of any rocking.You can double stick sandpaper onto a very flat and firm surface and slide the bottom across that. The problem with this approach is that sheet sandpaper is way too small. You can stick down several sheets and if you go very s...
I will start this blog the same way I started the one on making a Lazy Susan. Now before I get started on this little demonstration of how I do it, let me caution you on a couple things. IF you try anything like this, take the plate that your saw blade comes up through and close that hole completely up with a thin piece of wood. Make sure it is even with the top, with no gaps and no lips to catch the pieces. You want it smooth. Then with a “Hollow ground plywood blade” come up from the bot...
Well, now that I’m fairly comfortable with the layout and construction of the cabinet it was time to tear things apart and get some actual measurements and formulate a material list and plan of attack (much easier to tear virtual cabinets apart!). After saving the Sketchup plan as another file I start removing unnecessary and duplicate items and start putting-in some dimensions. The pictures should show most if not all of the dimensions I used, but I can’t say for sure since I...
Updated 1/15/12 Now we need to cut a recess in the lid for the medallion to set down into.DONT cut your medallion until you have routed out the home for it.I typically make the medallion about 1” to 1.5” smaller on all sides than the lid depending on the box size and the piece of wood I have for the medallion. We are now going to make a simple jig for a router to set on and run back and forth making several passes of incrementally deeper cuts. There are a several ways to do ...
Updated 1/16/12 This is the fun part! Its scary too! The idea of taking a nice crisp box, one you have spent countless hours making, and attacking it with a tool designed for slag removal is…well…its a little disturbing. Maybe I was influenced by old Hitchcock movies more than I know. Seriously, what I enjoy is the freedom this gives me. Everything up to this point has been tied to measurements and careful setups. This is where we can cut loose a little. But slow down Hot...
Part of my problem, which I assume all woodworkers have is that there is no such thing as scrap wood….thus the piles of ply and lumber everywhere. This leads me to where I am now, musing over a design or two to aid in my quest for floor space and for that matter to just be able to see my floor! At this point I grow weary of looking at sketchup and would like your thoughts. Picture #1 – the overall design, partly borrowed from the generic A frame you have all seen around, wit...
Updated 1/15/12 Regarding wood movement:Depending on the wood you use, where you live, and your own personal experience,y ou may want to allow more clearance.This is what works for me. I really dont allow for any movement at this stage. I know this sounds like trouble waiting to happen, but it works just fine for me. Even if we start off with a snug fit, we will still end up with a small gap around the perimeter. This is due to the final sanding and easing of the edges between lid and l...
(This post is based on a LumberJocks.com forum thread.) After completing my dust collection system installation, I turned to my air cleaner, the Delta 50-875. I had decided to install it just above my table saw—about 2/3rd’s of the way along the wall, where the intake would be in line with the front door and the outfeed inline with the ceiling mounted vent fan. After reading “Woodshop Dust Control” this seemed like the ideal placement and this location had the added be...
Updated 1/16/12 This is where you need to decide how you want to open your box. I mentioned at the outset about some of the different boxes I have made and how they hinge differently from one another. All are good, but you may have a preference in style or it may be your ability that decides for you. The pin hinge is what we will mainly be focusing on and was used on this box. Chapter 10 will discuss this style. The Deco box uses a standard brass butt hinge with a stop stra...
Updated 1/15/12 At this point we should have an assembled box, with corner splines, a recess cut into the body for the lid to set down into 3/8”, and a recess for the medallion cut into the lid that is also 3/8” deep, and the medallion cut to fit.DO NOT glue in the medallion yet! Next thing is to make the handle.I like to attach the handle by cutting a mortise in both the handle and the edge of the lid and slipping in a thin strip of wood, aka a spline. The spline is a scrap...
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