| Project by Nils | posted 639 days ago | 573 views | 2 times favorited | 19 comments |  |
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As I mentioned in some earlier posts, I had asked Santa for an Incra Precision Positioning jig for Christmas. Santa came through for me, and I have finally completed my first project made with the jig. My goal was to practice creating some dovetails and otherwise learning to use the jig.
Before I could use the jig, I needed to put a router table extension onto my old Craftsman 9” table saw, and install the insert I bought almost a year ago. So I finally got that done in January.
Then I could start using my new jig. 
As I said, my main goal was to create some sawdust, but I thought I might as well exercise some design sensibility. The first thing I did was come up with some dimensions that I thought would look good, remembering the “golden ratio”, or for the purposes of this box, 8” x 5”. That meant my stock should be 5” wide. And based on the dovetail router bits I had, part of a big Ryobi set, I was limited to making half-blind dovetails in 1/2” stock. Since I don’t have a planer or a working jointer (another project that has to be done eventually), I depended on Big Orange for my lumber – luckily they had 1/2×5 1/2” red oak lumber, and that’s what I used for the sides. The top and bottom are 3/4” stock, also 5 1/2” wide.
The bottom is joined to the sides with a simple rabbet, and I made a small chamfer around the edge to give it a bit of decoration. The lid is rabbeted to fit into the opening of the sides. 
Since I was already thinking about making the box look reasonably nice, even though it was just for practice, I wanted to make good handle for the lid. My grab bag of pen blanks from Woodcraft happened to have a piece of purpleheart that was just not the right size for a pen. But it would be great as a handle. I was imagining a sinuous shape, something like a breaking wave, that would contrast nicely with the very plain and square lines of the box itself. I traced out my ideas onto the purpleheart, then used the bandsaw to cut it roughly to shape. 
As I started in with the rasp to finalize the shape, I realized I really hadn’t cut off enough, and went back to the bandsaw. I did a lot of the overall shaping with a block plane as well. (When my wife first saw the handle, she said it looked like something the dog left – happily, she liked it when it was finished.)
The finish is two coats of clear water-based polyurethane on the purpleheart handle, with “Walnut” Danish oil followed by amber shellac on the box itself.
I definitely learned a lot in this first project. Probably the most important thing was how critical the dimensions of the stock is. Especially the width of the stock, especially when using an Incra jig for the joinery. Because of the way you cut the joints, you’re always working from the same side of the stock, which means that after making four joints, you have multiplied any dimension problem by four. I believe stock varied by between 1/64” and 1/32” in width along its length, necessitating some serious sanding to get the side assembly to lie flat on top and bottom.
-- Nils Davis, Menlo Park, CA
19 comments so far
grovemadman
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558 posts in 670 days
posted 639 days ago
Very good for a first project Nils! I mean really goooood. Nice workmanship. How did you Like working with the Purpleheart??? ; .) Tough stuff isn’t it?
-- --Chuck
davidtheboxmaker
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372 posts in 703 days
posted 638 days ago
Nice box Nils.
As you comment – precise dimensions are really important with the Incra.
I’m using the same jig as yourself. I’ve made 5 boxes so far, then run into problems with the cutter.
Hoping to get them resolved before too long.
Scott Bryan
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20754 posts in 720 days
posted 638 days ago
Very nice box, Nils. This incra jig has been on my wish list. I just haven’t convinced myself to spend the money yet. This definately helps me tip the balance in favor of committing to buying this jig.
Thanks for the post.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
Jiri Parkman
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603 posts in 710 days
posted 638 days ago
Beautiful box. And good presentation.
-- Jiri
motthunter
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2079 posts in 697 days
posted 638 days ago
looks good. I have thought about this also.. I decided to stay with my leigh for dovetails… What real advantage do you see for this over standard dovetail jigs?
-- making sawdust....
Paul D
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2125 posts in 646 days
posted 638 days ago
Really nice box Nils. I have the Incra Jig Ultra that I bought probably 8 years ago. You can definitely make some nice things with these Incra jigs.
-- Paul D, Atlanta GA
Jon Spelbring
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51 posts in 1151 days
posted 638 days ago
Very nice box! And I don’t think that the purple heart handle looks like doggy doo at all :-) !
You have motived me Nils. I’ve got the Incra TSIII with the positioning attachment, but so far, I’ve been using it mostly as just a tablesaw fence. Now, I’ll have to dig out the templates, and have a go at some dovetails and box joints. Thanks for the tip on the Incra’s fussiness over exact dimensions, I’ll keep that in mind.
-- To do is to be
Mario
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882 posts in 949 days
posted 638 days ago
nice project and thanks for the pics of the progress.
-- Hope Never fails
GaryK
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9537 posts in 886 days
posted 638 days ago
Looks like you suceeded! Great looking bok.
-- Gary, East TX -- The longest journey begins with a single step.
herbr
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138 posts in 966 days
posted 638 days ago
Very nice box-great for a first project with your new jig!
-- Spread love with our work
Robb
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356 posts in 832 days
posted 638 days ago
Those incra add-ons look like they help to make some great projects. Maybe someday I’ll take the plunge, too. Nice work! I like how the handle turned out; you were right in your design assumptions that it contrasts well with the square lines of the box.
-- Robb
John Gray
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1754 posts in 783 days
posted 638 days ago
Nice post I have the same Incra jig but have yet to use it.
-- Only the Shadow knows....................
CharlieM1958
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7670 posts in 1116 days
posted 638 days ago
Nice box, and a nice setup you’ve got there.
-- Charlie M. "Woodworking - patience = firewood"
lance
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168 posts in 886 days
posted 638 days ago
All around A+. Keep up the great work.
-- Bob Lance, DE
Blake
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2763 posts in 772 days
posted 638 days ago
Hey Nils, I’m glad to see you’ve got your Incra up and running. That box looks great, man! I haven’t even tried using it for dovetails yet. The only template I’ve used are for box joints. Excellent shaping of the handle. You’ve done a GREAT job of creating sawdust! All around very nice first box.
-- Check out my new website! http://www.blakeweberwoodworking.com
Bradford
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787 posts in 721 days
posted 638 days ago
I concur with everybody else. Nice box. I would love to own an LS positioner with the router attachment. I would live in my shop. I’d make a tool wall/murphy bed. That would be fun. Dreaming. I’ll take that plunge later. Then just wait. Boxes galore. Keep them boxes coming Nils.
-- so much wood, so little time. Bradford.
Nils
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138 posts in 762 days
posted 638 days ago
Thanks everyone for the really nice comments and great feedback! Over the next week or so I hope to post some additional information on using the Incra jig on my blog, for those who are thinking of taking the plunge. I know you can also refer to some postings from Blake and others about how much they love their Incras.
-- Nils Davis, Menlo Park, CA
Dominic Vanacora
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504 posts in 767 days
posted 637 days ago
WOW when the first project is this good where do you go from here. Nice project.
-- Dominic, Trinity, Florida...Lets be safe out there.
cajunpen
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5968 posts in 964 days
posted 620 days ago
Nice box Nils. I’ve got that same Incra set, but I haven’t had the patience to master it yet.
-- Bill - "Suit yourself and let the rest be pleased." http://www.cajunpen.com/