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Arc Leg Box

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Project by Anthony posted 176 days ago 1196 views 15 times favorited 13 comments Add to Favorites Watch

Yet another box. This one was built as a proof of concept to test out my idea on cutting the large cove on the lid. It is made of some scrap Mahogany and Poplar.

The first thing I did was cut the legs to rough size and then using a jig to hold them in place I used the table saw to cut the arcs. That was fairly simple and the little jig of plywood and scrapwood that I knocked together held them good for the machining.

I then made the box using my homemade miter sled on the table saw to make the miter joints. After the box was glued up I cut a 1/4” groove in each corner for the legs to sit in. After sanding I glued the legs to the box using woodglue.

Next I got started on the lid.

SAFETY WARNING! THIS INVOLVES CUTTING WITHOUT A BLADE GUARD AND ONLY USING ONE FENCE. EXTRA CARE MUST BE TAKEN TO SUPPORT AND GUIDE THE WORK PIECE. I USED GUIDES AND PUSH BLOCKS FOR EVERY CUT!

For this one I simply laminated two 3/4” thick pieces of Poplar together to obtain the final thickness. After cutting it to final dimensions I once again used the table saw to cut the cove. The difference is that I clamped a wooden fence over the blade so that the edge of the fence ran through the center of the blade. Then with the table saw running I raised the blade to what would be the final height of the cove cut (1 1/8”). This resulted in half the blade being buried in the fence. I then lowered the blade and taking very small cuts, maybe 1/16” – 1/8” of an inch at a time I ran each side through the blade using push blocks and guides. It took many times through and on the last one I took off only 1/32” and ran it very slowly to get a smooth surface but after it was all said and done I had the cove cut lid I wanted.

After completing the cove cuts on the lid I used the router table to plow out a rabbet that would allow the lid to fit into the top of the box. And even though my initial rendering did not call for a handle I made a quick one out of a piece of Mahogany.

The finish is simply three coats of hand rubbed satin poly.

In case anyone wonders, the computer generated picture is strictly for comparison of the initial concept to the finished project.

-- Anthony - "The blacksmith and the artist, reflect it in their art. They forge their creativity, closer to the heart"





13 comments so far

View JUC's profile

JUC

77 posts in 393 days


#1 posted 176 days ago

I have never cut a top [cove] this way. On my to do list. nice box, thanks for the picutures and explanation.
Jeffrey

-- If no one will ever see it, all the more reason to make it right

View Jim Jakosh's profile (online now)

Jim Jakosh

10263 posts in 1608 days


#2 posted 176 days ago

Sweet box, that large cove is very attractive! That is a neat way to cut it, too!!............Jim

-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!!

View nailbanger2's profile

nailbanger2

921 posts in 1646 days


#3 posted 176 days ago

http://www.youtube.com/watch?v=csOCkcCBR4U&feature=youtu.be

Vonhagen showed a unique way of doing this, very informative.

-- Wish I were Norm's Nephew

View aussiedave's profile (online now)

aussiedave

2785 posts in 327 days


#4 posted 176 days ago

A very nice box, the legs look great as does the whole build…You did a great job..well done.

-- Dave.......Keep calm and make more sawdust....

View SteveGaskins's profile

SteveGaskins

206 posts in 1090 days


#5 posted 176 days ago

Nice. I really like the cove top.

-- Steve, South Carolina, http://www.finewoodworkingofsc.com

View Prplhrtjarhead's profile

Prplhrtjarhead

80 posts in 609 days


#6 posted 176 days ago

Beautifully done.

-- "We'll preserve for our children this, the last best hope of man on earth, or we'll sentence them to take the last step into a thousand years of darkness." R. Reagan, "The Speech", 1964

View littlecope's profile

littlecope

2785 posts in 2005 days


#7 posted 176 days ago

Great Job Anthony, you do nice work!
Thanks for sharing it, and Welcome to LJ’s!

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View kdc68's profile

kdc68

1704 posts in 780 days


#8 posted 176 days ago

Wow! Great work Anthony….The cove looks perfect…thanks for sharing

-- Measure "at least" twice and cut once

View Monte Pittman's profile

Monte Pittman

10844 posts in 841 days


#9 posted 176 days ago

Very classy looking

-- Mother Nature created it, I just assemble it. - It's not ability that we often lack, but the patience to use our ability

View majuvla's profile

majuvla

2894 posts in 1370 days


#10 posted 176 days ago

Beautiful box!Thanks for safety tips, always good to know where danger comes from. Outstanding design and wood colour contrast.

-- Ivan, Croatia, Wooddicted

View Donna's profile

Donna

8 posts in 176 days


#11 posted 176 days ago

Love it

-- You'll never know if you don't try

View Anthony's profile

Anthony

107 posts in 215 days


#12 posted 176 days ago

Hey everybody, thanks for the great comments. So happy that I joined Lumberjocks, what a great way to share and learn.

-- Anthony - "The blacksmith and the artist, reflect it in their art. They forge their creativity, closer to the heart"

View OldWolfsWoodShop's profile

OldWolfsWoodShop

111 posts in 451 days


#13 posted 175 days ago

Great project, will be using this as a guide. Thank you

-- Making Sawdust is great stress relief...

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