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4K views 6 replies 3 participants last post by  Sylvain 
#1 ·
starting out

have almost all the rehabs done, time to clean and clear off my bench..
Wood Gas Vehicle Engineering Composite material

And bring a few boards of Poplar to the shop…getting tire of them sitting around upstairs, anyway..
Wood Textile Rectangle Hardwood Flooring


1/2" x 5-1/2" by around 24" long. Project Boards from Lowes…Went to cut one of these into 2 equal pieces…can't get to the tablesaw…I did have a mitersaw handy…
Wood Loom Creative arts Machine Tool


It did have a problem, though…swing arm and the guides want to weeble and wobble, so, I remove the mitre saw, flipped the frame over, and torqued down the loose bolts…very loose bolts. Not any more. Found the center of the board..
Table Wood Creative arts Art Tool


28" long saw, makes quick work and a bit of saw dust…
Wood Automotive tire Bumper Gas Tints and shades


Cut lines were square..at least the ones I made..
Wood Rectangle Automotive exterior Hardwood Flooring


But the Factory ends weren't…
Wood Flooring Gas Rectangle Tints and shades


So, I backed up a bit, marked a square line across, and cut one board…used that to mark the second. set those 2 aside, and cut two "Ends" at 6" long, checking the factory ends again…so, I had 4 sides for a box..
Wood Automotive exterior Automotive tire Motor vehicle Bumper


I also found some leftover plywood, from the Desk Project….seemed the right width, and was long enough to get 2 panels out of…one for a lid, one for a bottom..cut to length on that Stanley 358 Mitre box..
Hood Automotive tire Motor vehicle Wood Wheel

And, there is still enough Poplar leftover, for a second box build…after this one is done.

Made a run to Hobby Lobby, to pick up some hardware for the boxes…like latches and hinges….and a screwdriver or two to install the TINY screws..
Product Publication Font Rectangle Advertising


So, next up? Well, going to use Finger/Box Joints for the corners,,,so, I'll be laying those out next episode

Stay tuned..
 

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#2 ·
Finger joints

I clamped the two long side outside face to outside face..
Wood Hand tool Metalworking hand tool Gas Auto part


Edges were even, ends weren't quite there…Stanley #3 to even things up..needed a way to set the spacing for the fingers…
Wood Gas Engineering Metalworking hand tool Tool


Along with a few other tools…since I will be using that sized chisel to chop the waste, I used it to lay out the fingers, working towards the center from each edge…
Automotive tire Wood Brick Brickwork Tints and shades


Waste is marked with a dot….needed a way to keep both boards aligned, while moving them around in the vise..
Wood Gas Hardwood Stool Flooring


Simple and easy. Then slid the pair down in the vise, until they are a 1/4" or so above the bench's top…
Wood Motor vehicle Gas Automotive tire Bumper


Boards want to vibrate a bit, otherwise…and, I get to sit down on the job…
Musician Artisan Artist Wood Gas


Then flip the pair end for end, and layout the other end of the boards, make the saw cut….
Wood Wood stain Hardwood Plank Lumber


Have to keep things in order….IF I open this stack like a book..
Wood Rectangle Floor Flooring Wood stain


These are the outside faces…need to keep the "top" edge aligned….flip the book over onto it's face….
Wood Rectangle Floor Flooring Wood stain


This is the insides of the box…marked for top (T) bottom(B) Inside face (IN) and a number at each corner, intheory that I can keep track of which goes where…..right….set one of these aside, easier to chop one set at a time. had a bit of scrap..Ash….will use that to protect the top of the bench…
Wood Plank Hardwood Lumber Gas


Only marks on the outside face is a line from the marking gauge, I use that to start the chops at…I go 1/2 way down, and also left a little bit to the outside edge, for support…
Wood Tool Hardwood Gas Wood stain


Then flip the board over, and finish the chops…
Wood Hardwood Gas Flooring Wood stain


Then use these fingers to lay out on an end piece of the box…..marking it as to which corner it will be, and which is inside, top and bottom. make the saw cuts, then back to chopping out…
Wood Flooring Gas Tool Auto part


Then a test fit….once the chopping was done..
Wood Rectangle Composite material Gas Hardwood


Rinse….
Wood Typesetting Composite material Gas Engineering


Repeat…
Wood Wood stain Plank Hardwood Lumber


Until all 4 corners are done….
Next up? Grooves…each board will get 3 grooves….top panel, bottom panel, and a way to split the lid off…

Stay tuned….
 

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#3 ·
Finger joints

I clamped the two long side outside face to outside face..
Wood Hand tool Metalworking hand tool Gas Auto part


Edges were even, ends weren't quite there…Stanley #3 to even things up..needed a way to set the spacing for the fingers…
Wood Gas Engineering Metalworking hand tool Tool


Along with a few other tools…since I will be using that sized chisel to chop the waste, I used it to lay out the fingers, working towards the center from each edge…
Automotive tire Wood Brick Brickwork Tints and shades


Waste is marked with a dot….needed a way to keep both boards aligned, while moving them around in the vise..
Wood Gas Hardwood Stool Flooring


Simple and easy. Then slid the pair down in the vise, until they are a 1/4" or so above the bench's top…
Wood Motor vehicle Gas Automotive tire Bumper


Boards want to vibrate a bit, otherwise…and, I get to sit down on the job…
Musician Artisan Artist Wood Gas


Then flip the pair end for end, and layout the other end of the boards, make the saw cut….
Wood Wood stain Hardwood Plank Lumber


Have to keep things in order….IF I open this stack like a book..
Wood Rectangle Floor Flooring Wood stain


These are the outside faces…need to keep the "top" edge aligned….flip the book over onto it's face….
Wood Rectangle Floor Flooring Wood stain


This is the insides of the box…marked for top (T) bottom(B) Inside face (IN) and a number at each corner, intheory that I can keep track of which goes where…..right….set one of these aside, easier to chop one set at a time. had a bit of scrap..Ash….will use that to protect the top of the bench…
Wood Plank Hardwood Lumber Gas


Only marks on the outside face is a line from the marking gauge, I use that to start the chops at…I go 1/2 way down, and also left a little bit to the outside edge, for support…
Wood Tool Hardwood Gas Wood stain


Then flip the board over, and finish the chops…
Wood Hardwood Gas Flooring Wood stain


Then use these fingers to lay out on an end piece of the box…..marking it as to which corner it will be, and which is inside, top and bottom. make the saw cuts, then back to chopping out…
Wood Flooring Gas Tool Auto part


Then a test fit….once the chopping was done..
Wood Rectangle Composite material Gas Hardwood


Rinse….
Wood Typesetting Composite material Gas Engineering


Repeat…
Wood Wood stain Plank Hardwood Lumber


Until all 4 corners are done….
Next up? Grooves…each board will get 3 grooves….top panel, bottom panel, and a way to split the lid off…

Stay tuned….
Very nice work. Thanks for sharing!
 

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#4 ·
Inside grooves, lots of them

Ok, unroll the box…
Wood Rectangle Plank Wood stain Hardwood


Set up a jig, to hold each panel…set up the Stanley 45 to the final fence setting…
Motor vehicle Machine tool Wood Engineering Auto part


Do the groove for the top and bottom panels to sit in…
Wood Gas Engineering Machine Metal


Then check the panels for fit…
Wood Gas Engineering Audio equipment Machine


And trim to correct size….length and width, would rather trim things down to fit, than find out one is too small…
next, I needed one other groove milled. To where I can split the lid off. Short rods on the 45 were too short…
Automotive tire Wood Motor vehicle Vise Tread


Switched out to the long rods, and set up where the fence needed to be…and made a few grooves…
Wood Engineering Gas Machine Auto part


Then dry fit a bit
Wood Hardwood Tool Wood stain Lumber


Set up a bunch of clamps…
Wood Automotive tire Engineering Gas Rolling


Make a stack of cauls….
Wood Gas Tool Lumber Automotive exterior


And glued the mess together…and let it sit for a day….

Stay tuned…
 

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#5 ·
Flipping your lid

Ok…box came out of the clamps…needing a bit of clean up..
Wood Tool Hand tool Metalworking hand tool Gas


Between the Stanley #3 and the ROS with 80grit…
Wood Gas Font Metal Machine


Got all the fingers leveled, glue stains removed….slight bevels along the edges….needed to jig up a way to plough a few grooves..and not have to chase the box all over the bench…
Motor vehicle Automotive tire Wood Wheel Gas


Stanley 45 was preset while the inside groove were finished up…may have had it a tad too deep?
Wood Automotive exterior Gas Composite material Flooring


Or, maybe the plane was tipping a bit…should have added the cam rest…long sides were done…returned the box to the vise….easier to keep it steady….
Wood Composite material Roof Gas Urban design


Then, reset a marking gauge and ran that all around the lid….came back with a pocket knife, and split the lid off..
Tire Wheel Wood Bicycle Gas


Then a test fit to see if it will fit down onto the lip….it didn't…...lip was too fat. Tried a chisel…didn't like that…
Set up the Stanley 45 again….this time I added the cam rest. Had to adjust the long rods, and the fence. Set the depth stop on the moving skate to where I needed it to be…just taking a couple thin shavings to narrow the lip towards the inside of the box….
Wood Gas Machine Metal Motor vehicle


About like this….did all 4 sides, test fit…missed a spot…redid that…then another test fit…
Wood Automotive exterior Bumper Gas Composite material


Seems to fit. All that remains for this box…is some hinges, a latch, couple of handles, and a finish of some sort…may add corner brackets, later…
Wheel Automotive tire Tire Automotive wheel system Font


Options #1, or…
Automotive tire Motor vehicle Font Automotive wheel system Bicycle part


Option #2….handles?
Font Metal Auto part Fashion accessory Art


And a third option for a latch….we'll see…
Stay tuned ( there will be a second Poplar Box Project, but will use Dovetails instead..after this Project is done)
 

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#6 ·
Hardware, and stain..and a PIP

While out and about, Sunday…picked a few packs of brass corners..
Brown Rectangle Wood Font Metal


I can use these to protect the bottom corners of the box….thought about doing the lid, as well….didn't look right…
So..hardware? Set the box into the vise, easier to work on hinges and a latch, without chasing the box and the lid across the bench top…needed a pilot hole for those tiny screws…
Wood Nail Gas Stonemason's hammer Metal


Pair of needle nose Visegrips, and a small nail. Set the part in place, locate where a screw will go, hammer the nail into the spot…had some small screwdrivers to us, too
Hand tool Tool Wood Metalworking hand tool Wrench


Plus the hammer, and a small combo square…to help center items like handles, and space the hinges in from an edge..hinges got done, first…
Wood Automotive exterior Composite material Gas Auto part


Holes for the screws do not have counter sinks, too thin. Then rotate, and add the handles, next…
Wood Audio equipment Shipping box Gas Box


One on each end of the box…more or less centered…then the latch. Tried one latch..looked a bit too flimsy/bendy, tried a different one…
Automotive tire Wood Door Table Motor vehicle


Seemed to look more like it belonged here…close the latch..
Hood Wood Table Motor vehicle Automotive exterior


Then installed the brass corners, rotating the box until all the screws were in place. hand sanding as needed, as I went along…stirred up the new can of stain, and a new brush…and gave the box a coat of "Gunstock"
Rectangle Wood Table Hardwood Wood stain


PIP#1….once the stain was applied all over the outside, searched around for a rag to wipe off the excess…
Wood Plant Cabinetry Drawer Hardwood


PIP #2….letting this dry overnight…
Brown Wood Rectangle Table Plant


PIP #3….And see IF it needs a second coat of stain..or just a couple coats of shellac….

This little box took 1 and a 1/2 of the 4 boards I bought….may get a box or two more out of the remains?
Extra tools will get stored in these boxes ( with a label?) and stashed on a shelf in the shop….have a coffee can full of taps and dies…may do a rack to hold them all, and sized to fit in a box?
a Final PIP will be with the finish done….then I can start on the next box…
Stay tuned..
 

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#7 ·
Hardware, and stain..and a PIP

While out and about, Sunday…picked a few packs of brass corners..
Brown Rectangle Wood Font Metal


I can use these to protect the bottom corners of the box….thought about doing the lid, as well….didn't look right…
So..hardware? Set the box into the vise, easier to work on hinges and a latch, without chasing the box and the lid across the bench top…needed a pilot hole for those tiny screws…
Wood Nail Gas Stonemason's hammer Metal


Pair of needle nose Visegrips, and a small nail. Set the part in place, locate where a screw will go, hammer the nail into the spot…had some small screwdrivers to us, too
Hand tool Tool Wood Metalworking hand tool Wrench


Plus the hammer, and a small combo square…to help center items like handles, and space the hinges in from an edge..hinges got done, first…
Wood Automotive exterior Composite material Gas Auto part


Holes for the screws do not have counter sinks, too thin. Then rotate, and add the handles, next…
Wood Audio equipment Shipping box Gas Box


One on each end of the box…more or less centered…then the latch. Tried one latch..looked a bit too flimsy/bendy, tried a different one…
Automotive tire Wood Door Table Motor vehicle


Seemed to look more like it belonged here…close the latch..
Hood Wood Table Motor vehicle Automotive exterior


Then installed the brass corners, rotating the box until all the screws were in place. hand sanding as needed, as I went along…stirred up the new can of stain, and a new brush…and gave the box a coat of "Gunstock"
Rectangle Wood Table Hardwood Wood stain


PIP#1….once the stain was applied all over the outside, searched around for a rag to wipe off the excess…
Wood Plant Cabinetry Drawer Hardwood


PIP #2….letting this dry overnight…
Brown Wood Rectangle Table Plant


PIP #3….And see IF it needs a second coat of stain..or just a couple coats of shellac….

This little box took 1 and a 1/2 of the 4 boards I bought….may get a box or two more out of the remains?
Extra tools will get stored in these boxes ( with a label?) and stashed on a shelf in the shop….have a coffee can full of taps and dies…may do a rack to hold them all, and sized to fit in a box?
a Final PIP will be with the finish done….then I can start on the next box…
Stay tuned..
Nice looking box.

In this post , Paul Sellers uses a nail as drill bit. Good idea as real fine drill bits tend to snap easily while a nail will bend.
 

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