|Project by Boxguy||posted 05-19-2013 05:53 AM||2707 views||10 times favorited||43 comments|
Pictured: A 12×5 x 5 inch tea box for 40 bags, or a card box for 8 decks, or a plain box with this unit removed. This box can be all the above. Hence the title about embracing diversity.
A foil wrapped teabag and a standard deck of cards have the same height and width dimensions. So, I thought I would design a box to sell that could be diverse and do both jobs. It should sell to two different markets…tea drinkers or card players. The Venetian blind dividers lift out as a unit for cleaning, or if you just want a plain box.
Woods: The top of the box is American Walnut with a Honduran Mahogany strip sandwiched between two strips of Hard Maple. (Another time I’ll go through this process, but the hints are to start with a thick board and resaw it after the glue dries.)
The corner splines are sucupira, and the sides are quarter-sawn White Oak.
Focus: The 8 Venetian blind dividers are held in place by an insert that looks like this (above). In this post I would like to look at a jig designed to make this insert.
Here you can see the basics of the jig. It is made like a standard jig for box joints. You cut the first slot, put that cut slot over the extended (piece of blind) peg in the jig, and then cut the next slot. Notice the jig rides on two rails, but also rubs along the fence to take virtually all of the play out of the movement. There is also a stop fastened to the fence so you don’t cut too far forward and endanger your hand or cut the jig in two. For safety the blade is buried in the 2×4 piece with a cap on it so you are not in any danger of cutting your hand as the blade travels through the jig’s fence. The protruding placement peg is on a separate piece (walnut) of wood to help adjust it easily…then it is screwed to the jig fence when the projecting peg is in the right position.
This view shows that I have written the directions for using the jig and the dimensions for the box build on the jig itself. That way if I build more of these next year I’ll know just what to do.
Since my blade is 1/8 inch thick and Venetian blinds are 1/8 inches thick, I get a nice tight fit for the dividers in the insert.
The finished product looks like this.
Thanks: As always thanks for looking, and a special thanks to all who take the extra time to make comments or ask questions. I do respond to all your comments and question made within 24 hours of posting so check back for answers and responses. Keep boxing and keep posting.
-- Big Al in IN