|Project by FJPetruso||posted 09-30-2010 03:59 AM||1621 views||3 times favorited||4 comments|
My daughter wanted to give a unique birthday present for her friend’s kid. So my daughter figured that that good ole woodworker, Dad, would help make a toy box. The toy box she wanted was one like I made for my grandson on an earlier project. It was a smaller box constructed of birch plywood & put together with wooden bolts. She also wanted a larger box & we did some figuring & came up with 24-1/2” wide by 16-1/2” deep by 16-1/2” high. She also wanted to really participate in the construction of the toy box so we first went to the BORG (Home Depot) & she helped to pick out the wood. She even paid for it! (You know a father normally isn’t used to that kind of help.) She picked out some nicely figured birch plywood & I got some maple for the corner brackets. Back at home in the shop I have some oak boards & hardwood dowels to make the bolts. We cut out the panels for the sides & the bottom was cut from 1/4” plywood. The table saw was used to cut the groove for the bottom to fit in & also to cut shallow kerfs for the paneled look. While I was cutting the wood, my daughter was threading the dowel rods & making the bolts. We cut out some 1-1/4” square by 3/4” thick oak blocks & drilled holes in the center. My daughter wrote the child’s name out in a style resembling a child’s printing & I routed his name on the front panel. Then while I was cutting the corner braces from the maple she tapped the oak blocks & then we also tapped the brackets. I used the table saw again to make some trim for the top & bottom & after temporarily assembling the box I fitted the trim at the top & bottom using the only metal fasteners used in the toy box, wire brads from my brad nailer & some glue. Next, like all projects out of my shop, the toy box got it’s butt branded. My daughter sanded & stained the box with water base stain & then gave it three coats of clear water based sealer. With a little bit of scraping of some thick areas of finish, the final assembly of the toy box was completed.
-- Frank, Florissant, Missouri "The New Show-Me Woodshop"