Overview: In the last blog I detailed how to separate the top from the box and how to start with a long piano hinge then size, cut, polish, round, crimp, smooth, and paint the hinge so it will fit any size of box. In this chapter I will explain how to install a piano hinge in a box. We will go through how to mortise, fit and fasten the hinge. The essential tools are: router table, small try square, vix bit, drill and impact driver. If all goes well, it should look like this when you ar...
How do you make a hinge and fit it in a box so that it looks like this when you are done? You Could Use This!...My Hinge Station or a Hack Saw .. Just Browsing? If you want to casually breeze through this just read the dark print and look at the pictures. For more serious readers, I have included details in the fine print. Economics: Price is a major consideration if you are making boxes for sale. I simply can’t afford to put $35 or more into a set of fine brass hinges and m...
So I haven’t gotten to the ribs yet because I need a bending strap and they seem to be harder to get than they should be. First I tried ordering the sheet metal to make one from McMaster-Carr, but apparently I’m no longer considered an “established customer” so they canceled my order. It seems they don’t like to send stuff to Canada, go figure. Next I decided to order a ready made one from International Violin, but they’re back ordered, so I’ll just ...
Thanks for joining in again and I apologize for the delay. Hand is doing a lot better and it feels great to be back in the shop. Thanks for your patience and your encouragement to get better. In this section we will focus on shaping and sanding our pieces. In my opinion, this is the most important part of the process. Depth is what makes a piece really stand out and the more depth you use in your project the better you’re going to like the end result. We have all seen intarsia pieces...
Boxguy’s Spline Slot Cutting Jig Want to add corner splines like this?,, You need a jig like this!..This hard working (and dusty) jig is used on almost every box I make, and is quick and simple to build. It has a wide plywood board for a base, a long “trough” supported by 45 degree triangles cut from a 2X6 and a handle so you can pull it back to you. (I just made the handle out of a forking branch.) The long trough lets me use this for boxes that are large or smal...
This is the first project I have ever posted on any forum for any experts out there to comment on. So with a little trepidation I submit this to you all to comment on. I’m restoring an old gate leg table I made in 1980 from oak timbers salvaged from a local church tower which was built in 1492. http://j.mp/KU6Cs8. This is a link to the history of the church for any one who is interested. The timbers had to be replaced back in about 1980 due to insect infestation. I’ll wr...
Sharpening card scrapers was never so easy, or so much fun… This week is all about card scrapers: how to sharpen them, how to use them, we make a rack to store them and a jig to burnish them. Along the way we do some fooling around and talk about Roy Underhill’s mustache! There are two projects in this episode, a tool review and a detailed demonstration of cabinet scraping goodness. Check out more episodes at Stumpynubs.com. Enjoy!
The Greene brothers used ebony extensively in their furniture and architectural pieces and that use has become a trademark of their woodworking designs. I wanted to try to stay true to their designs and use actual ebony plugs in the Greene and Greene style clocks I am building. I was not impressed with the shouldered plug design the plans called for and wanted true pillowed ebony plugs in my clocks. Pricing Ebony, I decided that I would have to come up with some other method of getting my plu...
The Spline Cutting Jig I use this jig to make all my splines. Basically it is set up to use the band saw to cut triangles out of a long thin strip of wood. It is just a board with a runner for the guide slot and another board fastened at a 45 degree angle. Cutting small pieces on a table or radial saw is a disaster. Your fingers wind up in wrong places and the small pieces fly all over the shop (not good). This is a job for the band saw! If it is done well the splines will look ...
I have found an easy and very effective way to keep my rigid shopvac filter clean. I had some left over Orek filter bags so I cut them seven inches from the top and slipped them over the pleated filter, tucking in the tops of thebag to keep dust from leaking out. Well after three weeks the filter is 90% dust free, all I do is tap the bag and the dust fall off easily.I do not remove the bag. Unlike panty hose that does not do a good job the filter bag does its job. The Orek bags are lined and...
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