I’ve been reading the forums here for a while and I’m really impressed with the knowledge and accomplishments – very inspiring! As a beginner to woodworking myself I’d love to get your advice for some early projects.
The local hardwood lumber store sells “thins”: ¼” to 5/16” thick lumber planed on two sides. I thought I’d try my hand at making small (say, 6” x 4” x 3.5”) boxes from this stuff. I’ll be usng only unpowered tools because of space and noise restrictions.
Here’s what I’m thinking:
1. Plane one edge of the “thin” with a smoothing plane so it is square to the faces.
2. Measure and mark out the rectangles for the sides, top, and bottom using a combination square and knife/pencil.
3. Cut out sides, top and bottom on a bench hook using this Japanese saw I bought from LV: (http://www.leevalley.com/en/wood/page.aspx?p=32923&cat=1,42884,42924&ap=1) I’ll have to make a bench hook that accommodates the pull saw.
4. Use a shooting board and (yet to be purchased) low-angle block plane to true up the rectangles just cut out.
5. Measure and mark out finger joints on the ends of the sides.
6. Use a Dozuki-me saw (again already bought at LV: http://www.leevalley.com/en/wood/page.aspx?p=58686&cat=1,42884) to do the rip cuts for the finger joints – perhaps clamp two sides and cut together, then clamp two ends and cut together?)
7. Chisel out the finger joint waste
8. Create ¼”stopped grooves in the sides to take the top and bottom using a router plane (haven’t purchased that yet.)
9. Plane or sand the edges of the top and bottom so they fit in the grooves.
10. Assemble and glue it all up.
11. Mark out the separation between lid and box, and cut it in a vise with the Japanese saw in 3 above.
12. Use a chisel and the router plane to make recesses to take hinges.
13. Attach hinges to the lid and box.
14. Sand and finish.
I hope I haven’t already worn out my welcome by typing such a long message, but I’d really appreciate it if you would let me know if anything above doesn’t make sense, or if there might be better ways to go about it.
In the meantime I’m practicing trying to saw straight and to get finger joints that don’t look awful…
Thanks in advance!