To see the finished project go here:
Here is the sample piece to test the concept.
I started with wood planed down to 3/8”, cut to width and left a little long for trimming.
I used a 1/2” 45 degree router bit to make the grooves. They are spaces 1/2” apart and 1/4” deep, starting 1/2” from the edge. The width of your wood matters. 1/2” increments works great.
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To enclose and make the sides a full 1/2” I planed some 1/8” pieces.
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This is how they will be assembled. The inserts are left out of this picture.
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Here I cut the inserts at 45 degrees. If you have a right tilt saw just move the fence to the left of the blade.
This allows the pieces to fall away from the blade.
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Here are all the parts ready to be assembled.
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You will want to glue every other piece, since to assure that the inserts filled the grooves, I cut them a little big.
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Doing them all at once would not work.
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Here is the first set of inserts glued in and then re-planed back to 3/8”. I left the planer setup to 3/8” so it always cut the same.
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Make sure that you use a lot of clamps to get even pressure. I actually measured each insert and put the thicker ones on the outside and applied more clamp pressure in the middle.
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Here it is all glued and planed.
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Then I gluied the 1/8” pieces to close in the inserts and bring the thickness to 1/2”. Then I cut a 1/4” x 1/4” rabbet for the bottom. They were also cut to length.
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Then with the blade still set to 45 degrees I cut the kerf for the splines.
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Here is a fixture that I made to hold the part while I ran it over the table saw blade. Make sure that you use a pushblock the hold the wood down. I raised the blade 1/4 turn for each cut Until I reached the depth I wanted. Place a piece of tape to your saw near the handle at the point for your depth of cut. This will make it easy to get a repeat depth. Notice the clamp on my fence to hold it in place. Be prepared for a lot of sawdust!
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Here you can see it with it partially cut. I just flipped if end for end for the cuts. For the narrow cuts I used a 3/4” ball nose bit on the router table.
The rest of the construction is done just like you would any other box so I’ll stop here.
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Here is a good use for go-bars to clamp the inner sides while the glue dried.
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Another variation of the use of go-bars.
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-- Gary, East TX -- The longest journey begins with a single step.
























29 comments so far
BrianM
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114 posts in 143 days
posted 68 days ago
Gary,
Thanks for all your effort. It’s a great box and it’s really nice of you to do all that work and share the method to construct that box.
Your the best!
BrianM
-- There is no such thing as scrap wood!, http://www.saltrivergallery.com
Blake
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1811 posts in 265 days
posted 68 days ago
Shoot, Gary! I thought I knew how you did that but I was wrong! GREAT tutorial. Thanks for taking the time to photograph and blog it. Veeeeeeery clever.
-- Dust collectors suck.
trifern
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1924 posts in 158 days
posted 68 days ago
Excellent tutorial. Thanks Gary.
-- Depend on the rabbit's foot if you will, but remember it didn't work for the rabbit.
TomK
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337 posts in 265 days
posted 68 days ago
Well done how to!
-- North Texas
teenagewoodworker
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1689 posts in 159 days
posted 68 days ago
great job Gary. like i said before you’ve left us all dumbstruck again! thanks for taking the time to show us how to make this piece.
Ad Marketing Guy - Bill
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302 posts in 189 days
posted 68 days ago
Another of your absolutely FANTASTIC tutorials – this is clear, concise and and a great read.
THANKS for taking the time!
-- Bill - - Ad-Marketing Guy, Ramsey NJ
Karson
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11555 posts in 791 days
posted 68 days ago
Gary: A great use of your talents to design a great looking box. It looks fantastic.
-- Karson Southern Delaware karson_morrison@bigfoot.com
dlcarver
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228 posts in 121 days
posted 68 days ago
Gary, I agree with the teenager. Absolutely ingenious. I would never think of doing a job like that.
FABULOUS ! THANKS FOR POSTING!
DAVE
-- Dave Leitem,Butler,Pa.,http://dlcarver.etsy.com
Scott Bryan
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7813 posts in 213 days
posted 68 days ago
As usual, a very informative blog. You have taken a complex construction and broken it down into easily understood steps. Excellent photography too, by the way.
Thanks for the post. I enjoyed looking at this one.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
ND2ELK
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1851 posts in 165 days
posted 68 days ago
Hi Gary
Thanks for posting. It makes a great looking box. You did a beautiful job on it. Need to add this one to my favorites!
God bless
tom
-- Mc Bridge Cabinets, Iowa
alan coon
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28 posts in 104 days
posted 68 days ago
Gary, Very inventive ,fun to work the gray matter. Thanks
-- Al, South E. Az., But it's a dry heat.
Peter O
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624 posts in 265 days
posted 68 days ago
Wow, that is really cool!
You’ve given me an idea … if the contrasting inserts were round instead of triangular … and if you put them in after shaping the face of the walnut … then they’d be raised accents … yeah, I think that would be cool, too.
I must be having one of my more eloquent days.
-- What exactly is "The Move" and who are you calling a "Quirky Jerk"? -- http://www.north40custom.com
Russel
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1028 posts in 330 days
posted 68 days ago
The ability to see below the surface is a remarkable ability. I wish I had it. After seeing how you did this, I say, “Why didn’t I think of that.” Then, of course, I realize, I’m not that creative. Good process and great results Gary.
-- If at first you don't succeed, try again. Then quit. No use being a darn fool about it.
GaryK
home | projects | blog
8183 posts in 379 days
posted 68 days ago
Peter O – That’s another of my ideas that I have in the works. It would also work with the triangles.
Another is to vary the depth of the inserts to get other great designs.
I’ll do up some more sample boards and post them and some other ideas I have.
-- Gary, East TX -- The longest journey begins with a single step.
Les Hastings
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359 posts in 164 days
posted 68 days ago
Great blog Gary! You must have way to much free time on your hands. Ever see your wife much? :) ( just given you a hard time). This is really an excellent project,,,,,Kudoo’s.
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
Chips
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7 posts in 103 days
posted 68 days ago
wow The Best of the Best. Thanks for the how to.
-- Make every day the best day of your life. Chips, Mississippi
tomd
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81 posts in 161 days
posted 68 days ago
Thanks for the blog it was very informative. You are a very creative fellow.
-- Tom D
Dadoo
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1398 posts in 381 days
posted 67 days ago
Hey that’s real cool! Thanx for posting it!
-- Bob Vila would be so proud of you!
GaryK
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8183 posts in 379 days
posted 67 days ago
Here are a couple more variations on the theme. The first is the one that Peter O mentioned above.
It has the depth of cut varied also.
Here the insert was inserted after the cut.



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This is after.
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This shows both side by side.
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-- Gary, East TX -- The longest journey begins with a single step.
Peter O
home | projects | blog
624 posts in 265 days
posted 67 days ago
Gary, this is great stuff! Where do you find the time? The raised inserts look like a 3D optical illusion. Did you use dowels or did you use stock with a bullnose on one side? It occurs to me that with full-round, you’d have to be very careful not to go past half the thickness of the inserts or you’d have gaps.
Is that blood on your workbench?
-- What exactly is "The Move" and who are you calling a "Quirky Jerk"? -- http://www.north40custom.com
Kerry
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91 posts in 181 days
posted 67 days ago
Thanks for sharing this Gary. Very ingenious. I only hope someday my own imagination kicks in, because I would never have dreamed up anything like this.
Kerry
-- Alberta, Canada
GaryK
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8183 posts in 379 days
posted 67 days ago
Peter O – I’ve been asked before if that was blood. It’s dye.
To test this I just used dowels I had. I would use bullnose if I were doing this for real.
You are right about going more than halfway and having gaps.
I have a few more ideas that I am working on also. They are pretty exciting also. I hope any way.
-- Gary, East TX -- The longest journey begins with a single step.
Jeff
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941 posts in 485 days
posted 66 days ago
Very cool stuff Gary. It’s funny. I thought the variations that you just posted were how the box was done in the first place. When I read the process I was confused a little. I need to adjust the contrast on my monitor methinks! LOL. Thanks for giving us another technique in our toolboxes. Quite gracious.
-- Jeff, St. Paul, MN
lew
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457 posts in 146 days
posted 66 days ago
Gary,
I get soooo mad at you ;-)
Why can’t I think of things like this?!?
Lew
Grumpy
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3852 posts in 242 days
posted 65 days ago
Excellent blog Gary.
-- Grumpy - "Always look on the bright side of life"- Monty Python
grumpycarp
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134 posts in 137 days
posted 65 days ago
Beautiful as usual.
I misunderstood the title completely. I was thinking that for wood collection I just put a milk crate next to the chop saw and drop the offcuts into that but you were talking about something different . . . ;-)
Lee A. Jesberger
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2097 posts in 370 days
posted 64 days ago
Gary;
That was quite a photo session!
Very good both on presentation and techniques.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Woodhacker
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327 posts in 114 days
posted 57 days ago
Gary, I just stumbled across this …Wow. That is sooo cool!
I’m going to have to come back to this to absorb it all.
Thanks for sharing this technigue.
-- Martin, Kansas
davidtheboxmaker
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248 posts in 196 days
posted 57 days ago
Gary,
That’s a major contribution – thanks very much for the detail – its sets the mind to work on all sorts of variations. I also like the end-grain effect as seen in your picture of the mitres – must be some way of using that saw tooth effect as a decorative trim on the edge of a box.