|Forum topic by lumberjoe||posted 06-11-2012 05:55 PM||1282 views||1 time favorited||7 replies|
06-11-2012 05:55 PM
For fathers day, I want to make my father a fly box out of some curly oak I have lined with cork. The box is going to be fairly small, and due to tool limitations, I have questions about construction. The overall height is only going to be about 2 1/4 inches, and I am going to use either 1/2” or 3/8’ stock
Question 1 – Do I want to plane it to 3/8 or 1/2”? The stock is currently 23/32”. I don’t have a bandsaw yet so I can’t resaw. I know, a lot of nice wood is getting turned to chips
2- Joints. I want to assemble the whole box at 2 1/4” then cut it in half on the table saw. I am going to leave the blade about a 1/32” shallow and finish the rest with either a coping saw or exacto knife. I can’t dovetail it, I can’t box joint it so it will be mitered. I won’t have enough room for splines. Will the miters hold with just glue?
3 – Cutting the miters. I want to miter the top and bottom also so no end grain shows. Should I get a 45 degree chamfer bit, or cut it on the table saw? The end grain cuts will be done on the table saw to avoid tear out. I have a miter saw but I trust my table saw a lot more.
4 – Rather than get a chamfer bit, should I just get a lock miter bit? I am still concerned about tear out but I could make my cuts proud to allow some trimming.
5 – Hinges. I’d really like to use barrel hinges. Do I have enough room?
Sorry for asking a ton of questions, but I really want to get this right. My dad has undergone a lot of very serious health issues lately and I’m not sure how many more fathers days we will have.