|Project by Brad||posted 11-12-2015 06:24 PM||2052 views||17 times favorited||18 comments|
As soon as I finished cleaning up, sharpening and testing my “new” 45 planes in One, I discovered what a pain it was to have no place for it.
This looked awful:
And I worried that all the parts, accessories and accoutrements could easily get misplaced or damaged. So clearly, a box was needed to house everything.
I wanted to approximate the box design that the early Sweetheart #45s used. So I settled on the graphics from the image of a Sweetheart #45 cardboard box that I found on eBay.
The heavy plane and accessories called for sturdy material, in this case big-box-store pine ¾” thick for the top, bottom and sides. For joinery, I chose to mirror earlier-era Stanley boxes, and settled on 3/8” box joints. They came out nicely.
As to dimensions, I wanted the box to accommodate neatly housed accessories and the plane. And because I wanted a traveling plow/beading plane, it had to fit in the lower compartment of my Dutch tool chest. That led to interior dimensions of: 10 7/8” L x 7 7/8” W x 6 3/8” H and exterior dimensions of: 12 3/8” L x 9 ¼” W x 7 1/8” H. These numbers make for a snug, but organized, fit. If I had it to do over, I’d increase the dimensions to accommodate ¼” more interior length.
I started with the accessory docking board by building a prototype. This allowed me to finalize slot dimensions as well as to practice routing grooves and coves without blowing the piece apart.
A chamfer on the top edge of the docking platform better supports the seated plane.
After using my Rockler jig to cut the joints, I routed a ¼” groove for the bottom and a 1/8” groove for the sliding top. I’m kicking myself for not using the 45 for this, but I cut the grooves instinctually out of habit before I realized what I’d done! After that, I rabbeted the bottom to fit the grooves and glued up the box. Finally, I rabbeted the sliding top’s three edges to fit in the 1/8” groove. Were I to do this over, I would use a ¼” tongue because 1/8” is just too fragile.
To finish the lid, I added a section of pine to serve as a handhold.
The next step was to confirm that everything fit correctly (accessories and plane) into the docking station, then screw it to the box interior from the bottom.
At this point, the assembled box was ready for some graphics.
My choice of graphics favored coolness (to me) over accuracy. For the refinished cutter boxes, I downloaded graphics from a fellow Lumberjock.
Then I drafted the top-box decal in PowerPoint as well as the “One 45 Plane” graphic that goes underneath the “Stanley Tools” decal.
I couldn’t find a comparable font to draft my own “Stanley Tools” graphic so I cropped the one in the box image.
Then I inserted all the graphics into a Word document, printed them out and tweaked the image sizes until they looked “about right.” These I printed on full-page mailing labels using my brother’s fancy, schmancy HP Laser color printer. Then, to protect the decals, I applied three coats of Mod Podge Gloss Clear Acrylic Sealer. Next I peeled off the backing and affixed each decal to the box. To fix them in place and further protect them, I applied two coats of poly over the decals and box exterior.
At home in the Dutch chest
What a relief to find that my measurements were spot on and that the box fit neatly into the tool chest.
And that box is infinitely cooler than the cardboard home that it replaces. This project completes the outfitting of the chest. It’s ready to travel afar for use on projects as yet unimagined.
© 2015, Brad Chittim, all rights reserved.
-- "People's lives are their own rewards or punishments."