Another of these

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Project by thesoninlaw posted 01-12-2014 12:22 AM 1825 views 9 times favorited 17 comments Add to Favorites Watch

A while back, I posted one of these made of ash. I had a few requests for some build details. It is Pretty straightforward. Cut six square pieces of a size and thickness that you can cope edge-to-edge on your tablesaw. Miter all four sides of all six pieces and glue five of them together. Put the top in place and secure it with some double-face tape. Cope every face in both directions. I sand these with my drum sander. Attach a knob/lift of your choice by whatever means you like. That’s the quick and dirty rundown.

17 comments so far

View woodtickgreg's profile


211 posts in 2541 days

#1 posted 01-12-2014 01:01 AM

Yeah but there cool! Simple rules sometimes.

-- wood tick tools for turners by woodtickgreg @

View nonickswood's profile


533 posts in 1810 days

#2 posted 01-12-2014 01:10 AM

Very NICE!!

-- Nick, Virginia,

View cajunpen's profile


14566 posts in 3489 days

#3 posted 01-12-2014 02:37 AM

Who would have thunk it! Great looking box, simple, but unique.

-- Bill - "Suit yourself and let the rest be pleased."

View Monte Pittman's profile

Monte Pittman

21582 posts in 1761 days

#4 posted 01-12-2014 03:20 AM

Very unique, and unique is nearly always good

-- Mother Nature created it, I just assemble it.

View jrockflimflam's profile


8 posts in 1030 days

#5 posted 01-12-2014 04:46 AM

No matter how simple you make it sound; it’s above my thinkin skills.
Very cool. What kind of wood is it?

-- *The measure of a leader is not how much they know; it's how much they teach.* Jason

View thesoninlaw's profile


97 posts in 1208 days

#6 posted 01-12-2014 05:02 AM

Zebrawood and walnut.

View lanwater's profile


3111 posts in 2357 days

#7 posted 01-12-2014 06:17 AM

Very nice.

What’s the maximum height of your cove cut? I am guessing 3/8 from the pictures.
I am also guessing you started with 3/4 or 13/16 stock.

The top edge cove / pattern routing? It looks tapered as well then 45 miter on the inside?
I probably have it all wrong :)

Can you confirm please? I am interested in making one.


-- Abbas, Castro Valley, CA

View thesoninlaw's profile


97 posts in 1208 days

#8 posted 01-12-2014 07:37 AM

Your guesses on dimensions are right on track. I really didn’t measure, just set up some stops on my miter sled. In fact, all my cuts and coving were done on my miter sled. At coving time, I clamped the sled to the saw so it would not move. The top is made just the same way as the sides as described above. The first time I tried it was with plywood as it really was an experiment. I coved that top off of the box and it scared the hell out of me. I swore that if I didn’t find a way another way to hold the top while coving, I would not make another one of these. Double face tape fit the bill. Double-face tape it on and cove the top the same as the sides. As you progress up in blade height and are getting near your final few passes, stop coving the bottom so it doesn’t rest on sharp points (leave some little flats on the bottom corners). The real trick is getting the pieces very precisely square and very precisely mitered or it just won’t go together well at all and the top won’t sit down nicely. I mentioned that I sand these on the drum of my drum sander. Not only can you sand them this way, but you can ‘tune’ the coves and corners with careful sanding. The first one of these took a while. I’ve done another few and they are ready to finish in between an hour and an hour and a half from start to finish.
(Not including stepping away for a day while glue cures). Good luck.

View Nairb's profile


10 posts in 1066 days

#9 posted 01-12-2014 12:30 PM

What was the overall size of the squares that you started with and what is the dia. of your table saw blade?

View BritBoxmaker's profile


4607 posts in 2459 days

#10 posted 01-12-2014 03:42 PM

Interesting work and all the better for leaving out those ugly splines we see so much of.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View thesoninlaw's profile


97 posts in 1208 days

#11 posted 01-12-2014 04:40 PM

I have to guess that the squares were about 4.5”. As I said, I didn’t really measure, I just set everything up with stops for cuts that I could get max size and still have a comfortable thickness in the center after coving. I can’t go measure it as it is already gone. My wife tells me to stop giving stuff away and figure out how to market it. My blade is 8.25”. I know, I know. My 9” saw was purchased before I knew that new 9” blades are hard to come by. That should get better after I finish restoring my 1957 Craftsman King-Seeley 10” saw.
I have seen and admired a bunch of your work and for you to compliment mine is a big deal to me. I am so new at this. I completed my very first project in June of 2013. Thank you.

View lanwater's profile


3111 posts in 2357 days

#12 posted 01-12-2014 06:10 PM

Thanks Dave.

-- Abbas, Castro Valley, CA

View wb8nbs's profile


162 posts in 2116 days

#13 posted 01-13-2014 03:10 AM

It’s beautiful. And thanks for the explanation – I was guessing you had a saw with a much larger blade. Please make another one and shoot a video while you’re doing it.

-- The only difference between men and boys is the price of their toys.

View thesoninlaw's profile


97 posts in 1208 days

#14 posted 01-13-2014 04:32 AM

Sorry, but my life affords me very little time for woodworking, much less producing video (which I wouldn’t know how to do anyway). Regarding blade size, I was able to get a longer cove without a lot of blade height by doing the coving with my blade set at 45 degrees. Thanks. I will definitely be making more of these though, considering the feedback I have gotten here and the responses I have gotten from those I gave them to.

View roman454353's profile


4 posts in 1018 days

#15 posted 01-13-2014 06:40 PM

are you going to come out with the design plans that you used for this one? like specific ones

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