|Project by Don Johnson||posted 10-03-2012 12:32 PM||1261 views||3 times favorited||7 comments|
On the table in the pub where we had lunch during a day out on Exmoor last Saturday was a tray made from 5/8 inch thick plywood. It had two dividers, creating four compartments into which were placed salt and pepper pots and various packs of sauces and other condiments. “That’s just what I need”, said my wife, Avril, “to store my sewing ‘bits’ that I have to keep moving from my sewing room down to the lounge and back again – it just needs to be a little bit bigger”.
Well, a directive from SWMBO cannot be taken lightly, so I started thinking about how to satisfy her wish. Rather than use thick plywood and corner finger joints, I thought about repeating making a tray using the Britboxmaker method described at http://lumberjocks.com/BritBoxmaker/blog/17048 (but just using a router). I wouldn’t need to cut rebates/dados for a base as this would be ‘bottomless’ but used upside down, but instead cut some to locate the dividers.
I used some 1/4 inch oak-veneered MDF left over from another project, and very quickly cut the necessary grooves, both square and 45 degrees, and glued and clamped the tray – its such a simple method for something like this, and ends up with perfect joints without any effort.
For the dividers, I had one nearly square piece of similar 3/16 inch thick board, but its width was really just too short to make the longest divider – even though the grain was in the right direction across the board. So I set my saw to cut the correct width including the handle, intending to cut it lengthwise, but then got a ‘phone call. When I got back to the workshop I cut the board to the correct width, but across the board instead of lengthwise – Doh! I wonder how many times this has happened.
As I had no more board available of the correct thickness (I couldn’t recut the dados as the tray was by now glued) I had to use the cut piece – which just about stayed in the dados, but needed some filler to hid the gaps at the top. Anyway, Avril is delighted with the result, so once again my thanks to Britboxmaker for publishing his technique.
The fourth picture shows the tray with some ‘bits’ inside, sitting on one of Avril’s patchwork quilts.
-- Don, Somerset UK, http://www.donjohnson24.co.uk