About six weeks ago I received a catalog in the mail with a jewelry box on the cover. My wife saw the cover and asked me to make it. I guess I should not leave catalogs lying around and should take them to the shop. However, if I leave the catalogs in the house she will find something for me to make. Yes! A new project is born.
I ordered the box side and foot router bits together with the plans and hardware. When I saw the size of the box side bit at 2 ¾” tall and 1 ½” wide I knew that I would have to use a slow router speed. Thankfully, I had recently purchased a PC 890 variable speed router with a soft start to be permanently mounted in the router table.
I could have just stacked some feather boards together but half the fun for me is to make something. I measured an existing feather board so the new one would be approximately the same dimensions. Then I glued 4 pieces of ¾” MDF together and cut the kerfs on the band saw. It is not a pretty feather board but it sure does the job.
I carefully routed the sides and feet from one long board. Then I cut to dimension and marked each piece so I could get matching grain. I mitered the ends then glued it together. I must have used 10-12 clamps and right angle jigs. It turned out square. TADA I then cut the feet at a miter as well. I wanted to have the mitered ends of the feet match the box so I made a temporary box out of scrap and placed the jewelry box inside it and the mitered ends of the feet matched up very well. It would have been real tricky for me to glue the feet to the box since I have experienced slip on glued pieces before.
The hinges supplied with the plans had round head screws. After I mortised the hinges I installed them and found that it would not close all the way due to the round head screws. I tried a number of different ways including deepening the hinge mortise on the jewelry box. I didn’t want to mount one part of the hinge on the back of the lid since I wanted it to overhand the jewelry box by 3/8”. Nothing seemed to work. I then went to my local woodworking store, starting with the letter R, and bought some hinges with flat head screws. I then plugged the mortise on the jewelry box and started again. This worked great. I trimmed the lid and when I placed it on the jewelry box found that I had cut too much. Hint to self measure twice and cut once. So, I made another lid.
After sanding I sprayed a satin PolyAcrylic blend for the finish. After 4 coats and rubbing out between coats I was finally finished. Here are some pictures of the project.
-- Fred Childs, Pasadena, CA - - - Law of the Workshop: Any tool, when dropped, will roll to the least accessible corner.