After making the hinges and knob in Episode #9, it was time to return to the box again. I had taken the time to sand the sides as I went, so all that was left to sand were the panels. After that was done, I was left with a difficult choice. Both panels looked good as the top, and turned either way, forwards or backwards! I finally made the choice (probably the wrong one) and it was assembly time.
Clamped one side, with the handle next to the desired corner…
Then the Other…
This whole makes a surprisingly well-balanced package for Drilling the holes.
Set the depths of the holes..
Cut some pins out of dowel and sand the edges
One last thing before drilling, scoring a pilot, to start the drill in the correct spot
Drilling the hole:
When I tap in the pins, I form a sort of “sleeve” with my fingers to avoid snapping them in half while striking
Then I simply trim off the excess pins
I’m going to round over all the edges, but I start with a chamfer, marking it with some scrap 1/8” Lexan that’s kicking around
Then roughing those with the Scroll Saw tilted to 45°
I’ll spare you the filing and sanding
But when I’m satisfied, it’s time to part the top from the bottom. I try not to make more of this than it is. It seems when I’m most careful here, I have the least straight cut…This time I tried not cutting through entirely and then slicing it free with a Utility Knife. It seemed like more work having to clean it up afterward, but it worked too
After cleaning those edges a little, I clamped it up in my hinge attaching clamp
And set the hinge using a spacer strip. (Note: I also put pencil marks over the pivot pins, so I just line these up to the “break” in the box.)
This all took about four hours this morning, what with all the Picture taking…
I almost forgot, before I devoted the bench top to clamping and gluing, I took a minute to add a second coat of red paint to the knob. A couple quick squirts, wearing a freezer bag over my hand (all out of gloves) and Presto!
Now I’ll just wait until the glue dries or I get my next chance to get back to the fun, whichever comes first… :)
-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.