|Project by JoeinDE||posted 02-17-2010 01:21 AM||8664 views||4 times favorited||7 comments|
This is a fairly simple box, but it is functional and that is what I was after. I had about 3/4 of a full sheet of 3/4” ply (maple/birch) left from making the TV stand last year. I figured that my almost three year old son needed a toy box and that would be a good use for the rest of that sheet of ply. I bought the Rockler exclusive safety hinges and they have worked quite well so far. The handles are from the big box hardware store. This is my first experience with using edge banding; the big box store had birch and oak, so I used the birch and it goes well with the maple face that is the outside face. The screw hole plugs are something really dark that I got in a pack of cut-offs and scraps. The tray rests on runners so that it can slide left and right, but it is not attached so it can be removed to get to the area underneath. There is a divider in the bottom that is resting in dado slots and supported by the bottom. The stain is Minwax cherry and the finish is bulls-eye shellac. As you can see, my son has already loaded it with toys, so I didn’t get any pics without the toys.
Things that I learned in this project.
1. Powered sanders will very quickly sand through shellac and the stained layer if you accidentally push down to hard.
2. Even 3/4” plywood will warp when sitting in a garage for over a year. Unfurtunately I didn’t notice the warp until after I had put the carcass together. Based on the way I put the carcass together there was no way to true it so that the lid would match up perfectly when closed (there is about an 1/8” offset on the upper front left corner)
3. Painters tape is your friend if you want clean cuts in plywood from your table saw and you only have a combination blade for your table saw.
4. A block plane works well when trimming the overhang on the edge banding.
As always comments and suggestions are more than welcome.
-- A bad craftsmen blames his cheap #$%ing tools