|Project by mgb_2x||posted 01-23-2010 12:19 AM||2218 views||5 times favorited||6 comments|
I have always admired many of the nice projects that have been made using plywood, figured someday I would have to see what I could make. Sam’s really nice turning http://lumberjocks.com/projects/26802 was the final straw so to speak. Stopped by Home Depot and picked up some 3/4 inch BC and took a shot at a design on the fly. All through the build I had a fear that no matter what this would look like a piece of plywood, but the end result works for me. I learned a lot about using plywood will make a number of changes on the next round.
This is a snapshot of the process for those interested;
1 Build a box 13×10 x 5 1/2 tall mitre the joints and make a 1/8 inch groove for a bottom, cut bottom to fit, sand insides of sides and bottom, glue and assemble.
2 Build top frame 14 1/2 by 11 1/2 of 3 inch material miter corners. Creates 3/4 overhang. I added slipfeathers to the corners to strengthen the joint.
3 Build top insert of two thicknesses 6×10
4 Cut the cove on the box sides, see the photo, blade is set at 45 and rail guides are set a 45 to the blade. This configuration will create an eliptical cove which looks nice. Unfortunately mine is upside down, the tighter radius should probably be at the top, but since this is a protoype no big deal.
5 Cut the bevel on the frame and the insert, I run them on the table saw using a fence, very very carefully. Don’t recall the angles just use the trial and error method.
6 Lots of sanding, this method of creating a cove leaves a lot of saw marks, Plywood has a number of voids and I cut small slivers to fill some of the more noticeable gaps, others got a dab of CA. Assemble lid to box with small hinges, on this box I face mounted the hinges to the back of the box as I was not sure how good the screws would hold going into the edge of the plywood.
7 Cut 2 1/2 sqaures for feet bevel as needed.
8 Finish as desired, I used Golden Oak stain and a top coat of lacquer.
Took the box to the local woodworing store and got pretty good reviews along with some recommendations on how to improve the design. I would really appreciate any comments on how to improve the design, I know already I do not like the feet, they look too plywoody. Also need to get the eliptical cove headed in the right direction.
Thanks for looking!
-- "aim small miss small" m g breedlove