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Blog entry by kiefer posted 12-04-2014 04:25 PM 1829 reads 2 times favorited 7 comments Add to Favorites Watch

I am making two wing top boxes as Christmas presents somewhat like my VALET BOX
but these will have drawers in the ends .
I thought I would share the process in pictures .

This is the piece of Tamarac that I used but it has a lot of knots .

The board is cut and planed and cut into small pieces that are knot free .

Here is my messy bench full of presents in the making .
The tamarac pieces are getting assembled and marked into sides glued to jatoba strips .
The process takes several glue ups .
I use a melamine board as a nice flat and no stick assembly base .

Here the panels are starting to take shape.!

All the panels are sanded front and back and now onto the trimming .
I cut the ends using my sled and a pin which is an off cut from the divider strips and clamp it to the fence as an index pin to align the first cut and then use a stop block to cut the opposite end .
The front and back are cut with the setup but I have to ensure that the left and right sections are exactly the same length and the overall length is the same on all panels as the will be flipped end for end .
A couple sliding square make this an process easy .
All good onto the next step .

This is the end panel and I am cutting away the part that will be the drawer front .
The upper part will get a rabbet cut on the bottom edge and the lower part the drawer front will get a strip of jatoba glued to it to make up for the saw cut .

Here I am cutting the stopped dados that are for the dividers for the top section of the box (2) and the bottom section (1).
Again I am using my sled and with a sopb block to limit the travel of the sled .
All the dados for the centre and bottom plywood panels and drawer slide are cut next .
The picture shows the dados and they have to be precisely done .

Now the end posts and top cap are getting glued on and when the glue has set one more sanding and that is it it all the panels for two boxes ready for assembly.

The next entry will be about making the plywood panels and dividers and assembly of the box.

-- Kiefer

7 comments so far

View DocSavage45's profile


8706 posts in 3017 days

#1 posted 12-04-2014 06:16 PM


Lots of pictures! I sometimes screw up where I put the comments! LOL!

Thin boards being glued up. Melamine, good idea! I’m sure you have other efficient procedures? Do you use wax paper/ Clamping narrow stuff can be difficult and messy. Using white wood glue or ?

Thanks for sharing your process. Looks like once it is gone through many might be as easy as one?

-- Cau Haus Designs, Thomas J. Tieffenbacher

View Jim Jakosh's profile

Jim Jakosh

21530 posts in 3280 days

#2 posted 12-04-2014 08:51 PM

That is some nice accurate work, Klaus.Ii love it. Can’t wait to see the final product!!
Cheers, JIm

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!! Variety is the Spice of Life!!

View jbschutz's profile


545 posts in 2866 days

#3 posted 12-04-2014 09:38 PM

Looks good, Klaus. If it comes anywhere close to the Valet box, it will be a winner.

-- jbschutz

View kiefer's profile


5620 posts in 2841 days

#4 posted 12-04-2014 11:08 PM

Thanks Jim
So Far it turned out good all the sides are the same and the dados all match exactly .
I glued them up today and they are dead on square and level what else can a guy ask for I guess more good luck .


-- Kiefer

View kiefer's profile


5620 posts in 2841 days

#5 posted 12-04-2014 11:10 PM

This is going to be a slightly different design but close to the VALET box that I posted recently .
I am hoping .


-- Kiefer

View doubleDD's profile


7773 posts in 2218 days

#6 posted 12-05-2014 02:01 AM

That’s some very precise work you started there. The tamarac and jatoba look great together. I will be waiting for the finally.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View Roger's profile


20949 posts in 2978 days

#7 posted 12-07-2014 12:44 AM

Go Klaus, Go

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed.

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