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Box Making #8: Boxguy Big Als Box frame commences

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Blog entry by robscastle posted 05-21-2018 04:04 AM 2446 reads 0 times favorited 11 comments Add to Favorites Watch
« Part 7: Boxguy Big Al's SPLINE Box begins Part 8 of Box Making series Part 9: Boxguy Big Al's Spline Box the spline work starts »

I started off the frame of the Splined Box No 1 in honour of Big Al’s inspiring work.

I used a combination saw only this time … along with a few jigs you see in the pictures.

I marked out the timber to get the best bookmatch I could That meant using both pieces of the timber as I wanted the knot feature displayed on the front and back so I had to sacrifice the material reserved for base of the box to do this.

So a redesign on it will come later, not sure just what to do just yet.

The knot features are a bit hard to see but they are in the boards 2nd and 3rd from the right.

It wasnt without a series of problems.

1. Excessive splintering.

This was discovered on squaring the ends of the stock

I removed the blade and replaced it with a new one but the effect was no better on the second test cut

2. Saw not cutting at 45 degrees.

I did two test cuts and found the angles were way off, so out with the trusty Japanese Square and started checking the saw. I found the actual saw was touching on the vertical clamp post.
No end of checking corrected this problem, I needed thepost and clamp so the top section of the post got hacksawed off. Obviously never used it at 45 degrees before.
I also fitted a 45 deg ZCI in an effort to reduce splintering.

Have a look at the post and you can see the section I removed, next I then found the clamp handle touched the saw so as I had to use it albeit in a less than optimal position it stayed.

All a bit of a poor effort design wise on Ozito’s behalf for the saw, and considering I paid big bucks (almost $100) for it I was a little surprised. (see note below)

I have to add a Note here:
I found out later the recommendation is to swap it to the other side, (RTFM + moon slap)
With those issues fixed I began sawing away.

I did a dry fit up and sat the frame on the lid to see if any adjustments were required.

All looked as close as I could get, so I then dry clamped it together to check again.

View 1.

View 2.

View 3.

View 4.

As it looked good enough to glue up I dismantled it all and glued it up and reclamped it, I found the Kreg Table was too hard to use so resorted to my framing clamps,I did use the flat surface though.

I am hoping the splintering will not be too noticable.
That’s what you get, I guess for using rubbish tools and wood.

Thats all for today, I am now off looking for material for a replacement base now, and will continue on tomorrow.

-- Regards Rob



11 comments so far

View Boxguy's profile

Boxguy

2737 posts in 2408 days


#1 posted 05-21-2018 04:32 AM

Rob, the suspense builds. I like the start. I would have used the band clamps to clamp this. The band clamps, if tightened enough sort of even out the corner joints. I have never made a box of this shape. What a challenge. Leave it up to you to do a wild box like this. I am impressed. Looks much like the coffin you once built for the back of your truck.

For other LJs, here is a blog on the band clamps, I know you have a set.

This is a blog on a jig to cut 45s while leaving the saw set at 90. It wouldn’t be worth making the jig unless you were going to make several boxes.

Thanks for the mention. I am posting my latest box (of course it has splines) later. I built it in honor of the Hawaiian Volcano. Here’s a preview.

Keep boxing and keep posting.

-- Big Al in IN

View degoose's profile

degoose

7238 posts in 3495 days


#2 posted 05-21-2018 06:02 AM

Looking good mate…

-- Don't drink and use power tools @ lasercreationsbylarry.com.au

View robscastle's profile

robscastle

5313 posts in 2345 days


#3 posted 05-21-2018 06:20 AM

Big Al I had your clamps out but I didnt use them.

So here is a shout out as a form of recognition.

Plus I checked out your jig, where did you get the hardware for the build?

That volcanic eruption is a nasy bit of gear I have been watching it on the NEWS.

-- Regards Rob

View LittleBlackDuck's profile

LittleBlackDuck

2000 posts in 962 days


#4 posted 05-21-2018 09:04 AM



..... All a bit of a poor effort design wise on Ozitos behalf for the saw, and considering I paid big bucks (almost $100) for it I was a little surprised…..

Sorry rc, I stay clear of Pierre Cardin tampons, but I do believe in just a little bit of quality when it comes to my tool. Ozito is good for the home handyman that want’s to convince the missus that they should get a professional to do the job… alternatively use it as a boat anchor… now…, a boat is too expensive for me, so I stay way clear of Ozito.

We all can’t afford a Porsche but we don’t have to go through a pub drive through on a mangy old mule with bowel problems and bad breath…. perhaps a good Jap saw is a fair compromise if you don’t want to kill electrons.

PS. I’m prepared to sell your wallet back to you… finders fee has already been deducted.

-- If your first cut is too short... Take the second cut from the longer end... LBD

View robscastle's profile

robscastle

5313 posts in 2345 days


#5 posted 05-21-2018 09:48 AM

I hear you LBD, I have a $400 Einhell combination saw and I should have used it.
In fact after I experienced the problem I went to check The Einhell and noticed it was already shortened so I must have had the same problem some time ago, (like 2013) and modified it as well.
Same diameter however a solid post as opposed to a tubilar Ozito one.
Should have just swapped out the saws there and then, would have saved a lot of time repeating what I had already done.

After finishing for the day I decided to see if I could buy a replacement post on the net.

It seems Einhell bought Ozito (Which BTW short for Ozzie Tools) however the name Einhell has all but dissapeared as a brand and Ozito is soley retailed by you guessed it, ...Bunnings.

Next time I am at Smiths I will ask a fitter if they would turn me up another post. (or just live with the short one)

-- Regards Rob

View LittleBlackDuck's profile

LittleBlackDuck

2000 posts in 962 days


#6 posted 05-21-2018 01:47 PM

You do too much research! Spend some of that time driving down to Churchill!


... (Which BTW short for Ozzie Tools)...

Hope that’s not a play on words or I’ll burn my Ozzie naturalisation and put my hat in to be a politician!

..... After finishing for the day I decided to see if I could buy a replacement post on the net…..

Sorry rc, but i must,

One (or maybe two of us) must place a cost on our time… something that most LJ’s tend to ignore… the time we have left on this earth is worth far too much for too little return… so, time is NOT cheap… I started with $20 ph but as I get older it has inflated to $50ph (with my weight)...
If you cannot recoup that cost, spend the shekels on luxuries as opposed to writing off that precious life line!

Back on solid ground and my feet need washing!

SKI, SKI, SKI!

-- If your first cut is too short... Take the second cut from the longer end... LBD

View Joe Lyddon's profile

Joe Lyddon

10265 posts in 4193 days


#7 posted 05-21-2018 07:28 PM

Very COOL box… I like the jig that lets you cut 45 leaving the blade at 90...

-- Have Fun! Joe Lyddon - Alta Loma, CA USA - Home: http://www.WoodworkStuff.net ... My Small Gallery: http://www.ncwoodworker.net/pp/showgallery.php?ppuser=1389&cat=500"

View robscastle's profile

robscastle

5313 posts in 2345 days


#8 posted 05-21-2018 09:29 PM

The Couch interviews Andrew Scully and Sam Jovanou

https://www.youtube.com/watch?v=Gf6F65yTn2A

-- Regards Rob

View LittleBlackDuck's profile

LittleBlackDuck

2000 posts in 962 days


#9 posted 05-22-2018 01:54 AM



The Couch interviews Andrew Scully and Sam Jovanou

Checked out the vid (thx for not offering up reading material) and was nearly convinced, if not for my past experience…

Naturally the company owners will say its a great product… hey I think I’m a great guy but I have 2 ex wives that say different… all to their own!

But again I have digress… Your scrappy (with an “s”... for matterial used) project is coming on well…

-- If your first cut is too short... Take the second cut from the longer end... LBD

View robscastle's profile

robscastle

5313 posts in 2345 days


#10 posted 05-23-2018 08:04 AM

So I take thats a stamp of approval?

-- Regards Rob

View LittleBlackDuck's profile

LittleBlackDuck

2000 posts in 962 days


#11 posted 05-24-2018 12:20 AM

Quack!

-- If your first cut is too short... Take the second cut from the longer end... LBD

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