Boxes #2: Additional Boxes

The first box went well so I embarked on 3 more and one small one. I am making these boxes for the layout tools that I recently finished up.

Selection of the wood was what I had on hand, purchased for something else that did not get made. 1/4” x 2-1/2” x 48” Oak. I wanted to have a wrap around for the grain, so this worked out great.

Laid out the boards, cutvto length, checked to ensure I had matching lengths, tad bit trimming. Marked out all of the finger joints and groves, Marking the waste. Helps me not to make a mistake when I cut every. I also marked the top edge.

Over to the shop made box joint jig at the table saw.

Cut all of the fingers using the stacked dado set. While the dado set was installed set the fence and ran the boards through for the groves to hold the panels. Put a standard blade back in, set the fence to cut the grove that will form the recessed edge on the inside of the top.

A little fine tuning was required, thin strip of wood wrapped with 100 grit sandpaper. I then obtained the required size for the panels (1/4” Maple plywood, sitting around from a previous project). I cut them to size and fitted.

Almost ready for glue up. First I sanded both sides of the panels with 120 on the ROS. I also sanded the inside of all the pieces for the boxes. Then the glue up starts, try to be quick. I use a small 1/4” brush to spread the glue on all finger surfaces .

While thise are setting for a bit, time for a small box. Fellow LJ wants to barter. So I felt a box would be required fir presentation and storage. Used the drops from the first 3, ripped down a tad for the proper size. Then repeated the process, this time I used the router for all of the groves, then the jig saw to cut the fingers. Fine tuned and glued. The panels for this one was 1/8” Baltic plywood.

Sanded all the proud fingers on the belt sander, followed with the ROS for all of the sides. Since I used a dado blade I need to fill the ends with small pieces, 1/8” x 1/8” stock, started with about 6 pieces about 3” long. Glued the end in the little hoke and cut the excess with wire cutters. After dried sanded flush. (No more holes, and no one will know, it’s end grain).
No photos here.

Next up was to set the fence to cut the lid off. I set it so I could create a lip on the inside of the lower section. This is accomplished by cutting at the edge of the grove on the inside, towards the bottom of the box. This time I cut it just deep enough to leave a paper thin strip between the grove bottoms. Then using a utility knife sliced through, the box is open.

Then it’s a matter of sanding, using 100 grit wrapped around a block of wood. The top is just enough to remove any saw marks and fuzzy corners. The bottom is about the same, except one needs to use more sideways pressure to remove enough for the top to fit onto the bottom.

The inside, showing the lip that was created.

The small box.

And the inside

Thanks for reading and comments always welcome.

-- Eric, building the dream. the "Loft"