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5K views 18 replies 7 participants last post by  bandit571 
#1 ·
Back story

Ok..wanting to at least build something…my normal Hardwood supplier is off on "Holiday" to The Land Down Under until about March,,grrrr. Wound up heading to Lowes, instead. They "won" by default, as Menard's was way too high on their hardwoods…as in OUCH. Lowes sells a "Project/ Craft" line of woods….Pine (clear) Poplar, and Red Oak.

Looked for the 1/2" x 6" Pine…..NADA
Glanced at the Poplar version….my fingers looked straight ( ain't saying much)
Which left …Red Oak. Apparently the sticker was wrong, as to price. 4 boards 1/2" x 5-1/2" x 48", set #4 back in the rack..would have made a decent Long Bow….walked up to pay…OUCH! $22.and change..EACH! Well, it will just have to do. There goes the Tool Budget until next month…
Brown Wood Rectangle Table Tints and shades


3 boards…Almost $65 bucks sitting there.
Wood Rectangle Table Plank Wood stain


At least they are flat and straight…one even has some nice grain to it..
Automotive tire Wood Grey Wood stain Tread


But, what to build with this stuff? Let the boards sit a day in my house, while I go surfing the net….

Paul Sellers has a Video series called Master Class….and there is even a FREE series. Where he builds a project, start to finish, and explains each step. You can even download a set of plans! So…watched a project build about a Keepsake Box, with curved sides…the bottom and the top are floating panels. He builds the box, then saws the lid free…Looked like something I could do…...

Plans: 3 pages…
Handwriting Rectangle Font Material property Parallel


Handwriting Rectangle Font Parallel Pattern


Font Engineering Parallel Schematic Rectangle


Rectangle Font Pattern Art Paper


Rectangle Slope Parallel Font Handwriting


There is a cutting list, too…
Handwriting Rectangle Font Material property Parallel


And signed…
Handwriting Font Writing Paper Paper product


Well, since the bench is a mess…
Wood Tool Engineering Gas Toolroom


Spent a day putting most of this stuff away…kept a few tools out..
Wood Composite material Gas Machine Tool


Now, this bench is not all that big..
Wood Machine tool Table Tool Gas


So, the top needs to be clear, before something LONG can be set down on it…
Wood Hardwood Composite material Plank Gas


Then cleaned off the Mitre saw..
Wood Gas Machine Metal Hardwood


As it will soon have some work to do….while I try to memorize all the steps in the videos….

Stay tuned…
 

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#2 ·
Back story

Ok..wanting to at least build something…my normal Hardwood supplier is off on "Holiday" to The Land Down Under until about March,,grrrr. Wound up heading to Lowes, instead. They "won" by default, as Menard's was way too high on their hardwoods…as in OUCH. Lowes sells a "Project/ Craft" line of woods….Pine (clear) Poplar, and Red Oak.

Looked for the 1/2" x 6" Pine…..NADA
Glanced at the Poplar version….my fingers looked straight ( ain't saying much)
Which left …Red Oak. Apparently the sticker was wrong, as to price. 4 boards 1/2" x 5-1/2" x 48", set #4 back in the rack..would have made a decent Long Bow….walked up to pay…OUCH! $22.and change..EACH! Well, it will just have to do. There goes the Tool Budget until next month…
Brown Wood Rectangle Table Tints and shades


3 boards…Almost $65 bucks sitting there.
Wood Rectangle Table Plank Wood stain


At least they are flat and straight…one even has some nice grain to it..
Automotive tire Wood Grey Wood stain Tread


But, what to build with this stuff? Let the boards sit a day in my house, while I go surfing the net….

Paul Sellers has a Video series called Master Class….and there is even a FREE series. Where he builds a project, start to finish, and explains each step. You can even download a set of plans! So…watched a project build about a Keepsake Box, with curved sides…the bottom and the top are floating panels. He builds the box, then saws the lid free…Looked like something I could do…...

Plans: 3 pages…
Handwriting Rectangle Font Material property Parallel


Handwriting Rectangle Font Parallel Pattern


Font Engineering Parallel Schematic Rectangle


Rectangle Font Pattern Art Paper


Rectangle Slope Parallel Font Handwriting


There is a cutting list, too…
Handwriting Rectangle Font Material property Parallel


And signed…
Handwriting Font Writing Paper Paper product


Well, since the bench is a mess…
Wood Tool Engineering Gas Toolroom


Spent a day putting most of this stuff away…kept a few tools out..
Wood Composite material Gas Machine Tool


Now, this bench is not all that big..
Wood Machine tool Table Tool Gas


So, the top needs to be clear, before something LONG can be set down on it…
Wood Hardwood Composite material Plank Gas


Then cleaned off the Mitre saw..
Wood Gas Machine Metal Hardwood


As it will soon have some work to do….while I try to memorize all the steps in the videos….

Stay tuned…
This should be a good one watching a galoot do it all by hand. I'll enjoy this one. S4S wood to start with means it's something I could probably achieve myself. Everything past that I enjoy hand tool wise.
 

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#3 ·
Back story

Ok..wanting to at least build something…my normal Hardwood supplier is off on "Holiday" to The Land Down Under until about March,,grrrr. Wound up heading to Lowes, instead. They "won" by default, as Menard's was way too high on their hardwoods…as in OUCH. Lowes sells a "Project/ Craft" line of woods….Pine (clear) Poplar, and Red Oak.

Looked for the 1/2" x 6" Pine…..NADA
Glanced at the Poplar version….my fingers looked straight ( ain't saying much)
Which left …Red Oak. Apparently the sticker was wrong, as to price. 4 boards 1/2" x 5-1/2" x 48", set #4 back in the rack..would have made a decent Long Bow….walked up to pay…OUCH! $22.and change..EACH! Well, it will just have to do. There goes the Tool Budget until next month…
Brown Wood Rectangle Table Tints and shades


3 boards…Almost $65 bucks sitting there.
Wood Rectangle Table Plank Wood stain


At least they are flat and straight…one even has some nice grain to it..
Automotive tire Wood Grey Wood stain Tread


But, what to build with this stuff? Let the boards sit a day in my house, while I go surfing the net….

Paul Sellers has a Video series called Master Class….and there is even a FREE series. Where he builds a project, start to finish, and explains each step. You can even download a set of plans! So…watched a project build about a Keepsake Box, with curved sides…the bottom and the top are floating panels. He builds the box, then saws the lid free…Looked like something I could do…...

Plans: 3 pages…
Handwriting Rectangle Font Material property Parallel


Handwriting Rectangle Font Parallel Pattern


Font Engineering Parallel Schematic Rectangle


Rectangle Font Pattern Art Paper


Rectangle Slope Parallel Font Handwriting


There is a cutting list, too…
Handwriting Rectangle Font Material property Parallel


And signed…
Handwriting Font Writing Paper Paper product


Well, since the bench is a mess…
Wood Tool Engineering Gas Toolroom


Spent a day putting most of this stuff away…kept a few tools out..
Wood Composite material Gas Machine Tool


Now, this bench is not all that big..
Wood Machine tool Table Tool Gas


So, the top needs to be clear, before something LONG can be set down on it…
Wood Hardwood Composite material Plank Gas


Then cleaned off the Mitre saw..
Wood Gas Machine Metal Hardwood


As it will soon have some work to do….while I try to memorize all the steps in the videos….

Stay tuned…
I am very tempted to do it also.
As usual, interesting tricks shown in the videos
Among many of them, the rebate on the tail boards which will hide the grooves for the top and bottom, how to cut it after gluing and how to install the hinges.

For those not familiar with the P.S. projects:
I don't rely blindly on the plans. Regularly people find (or think) there are errors in the measurements.
I usually adjust the measurements to the material available anyway.
It is good to look at all the episodes and read all the comments before starting. (not that all comments are meaningful of course).

Looking forward to your implementation.
 

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#4 ·
Back story

Ok..wanting to at least build something…my normal Hardwood supplier is off on "Holiday" to The Land Down Under until about March,,grrrr. Wound up heading to Lowes, instead. They "won" by default, as Menard's was way too high on their hardwoods…as in OUCH. Lowes sells a "Project/ Craft" line of woods….Pine (clear) Poplar, and Red Oak.

Looked for the 1/2" x 6" Pine…..NADA
Glanced at the Poplar version….my fingers looked straight ( ain't saying much)
Which left …Red Oak. Apparently the sticker was wrong, as to price. 4 boards 1/2" x 5-1/2" x 48", set #4 back in the rack..would have made a decent Long Bow….walked up to pay…OUCH! $22.and change..EACH! Well, it will just have to do. There goes the Tool Budget until next month…
Brown Wood Rectangle Table Tints and shades


3 boards…Almost $65 bucks sitting there.
Wood Rectangle Table Plank Wood stain


At least they are flat and straight…one even has some nice grain to it..
Automotive tire Wood Grey Wood stain Tread


But, what to build with this stuff? Let the boards sit a day in my house, while I go surfing the net….

Paul Sellers has a Video series called Master Class….and there is even a FREE series. Where he builds a project, start to finish, and explains each step. You can even download a set of plans! So…watched a project build about a Keepsake Box, with curved sides…the bottom and the top are floating panels. He builds the box, then saws the lid free…Looked like something I could do…...

Plans: 3 pages…
Handwriting Rectangle Font Material property Parallel


Handwriting Rectangle Font Parallel Pattern


Font Engineering Parallel Schematic Rectangle


Rectangle Font Pattern Art Paper


Rectangle Slope Parallel Font Handwriting


There is a cutting list, too…
Handwriting Rectangle Font Material property Parallel


And signed…
Handwriting Font Writing Paper Paper product


Well, since the bench is a mess…
Wood Tool Engineering Gas Toolroom


Spent a day putting most of this stuff away…kept a few tools out..
Wood Composite material Gas Machine Tool


Now, this bench is not all that big..
Wood Machine tool Table Tool Gas


So, the top needs to be clear, before something LONG can be set down on it…
Wood Hardwood Composite material Plank Gas


Then cleaned off the Mitre saw..
Wood Gas Machine Metal Hardwood


As it will soon have some work to do….while I try to memorize all the steps in the videos….

Stay tuned…
I was gonna say those are some nice drawings you made. Then I seen they are from Paul Sellers site.
 

Attachments

#5 ·
Back story

Ok..wanting to at least build something…my normal Hardwood supplier is off on "Holiday" to The Land Down Under until about March,,grrrr. Wound up heading to Lowes, instead. They "won" by default, as Menard's was way too high on their hardwoods…as in OUCH. Lowes sells a "Project/ Craft" line of woods….Pine (clear) Poplar, and Red Oak.

Looked for the 1/2" x 6" Pine…..NADA
Glanced at the Poplar version….my fingers looked straight ( ain't saying much)
Which left …Red Oak. Apparently the sticker was wrong, as to price. 4 boards 1/2" x 5-1/2" x 48", set #4 back in the rack..would have made a decent Long Bow….walked up to pay…OUCH! $22.and change..EACH! Well, it will just have to do. There goes the Tool Budget until next month…


3 boards…Almost $65 bucks sitting there.


At least they are flat and straight…one even has some nice grain to it..


But, what to build with this stuff? Let the boards sit a day in my house, while I go surfing the net….

Paul Sellers has a Video series called Master Class….and there is even a FREE series. Where he builds a project, start to finish, and explains each step. You can even download a set of plans! So…watched a project build about a Keepsake Box, with curved sides…the bottom and the top are floating panels. He builds the box, then saws the lid free…Looked like something I could do…...

Plans: 3 pages…










There is a cutting list, too…


And signed…
Handwriting Font Writing Paper Paper product


Well, since the bench is a mess…
Wood Tool Engineering Gas Toolroom


Spent a day putting most of this stuff away…kept a few tools out..
Wood Composite material Gas Machine Tool


Now, this bench is not all that big..
Wood Machine tool Table Tool Gas


So, the top needs to be clear, before something LONG can be set down on it…
Wood Hardwood Composite material Plank Gas


Then cleaned off the Mitre saw..
Wood Gas Machine Metal Hardwood


As it will soon have some work to do….while I try to memorize all the steps in the videos….

Stay tuned…
I usually give credit to the people that provide the drawings….in case someone else wants a copy. In this case, it was Paul Sellers Masterclasses site.
 

Attachments

#6 ·
Tails first?

Strange as that might seem, as I normally cut pins first. But, to make this come out right, I need to do tails first..

Need a few boards cut to size, first. Layout the cross cuts…
Wood Composite material Hardwood Gas Plank


Bad end, large square to lay out a few cuts, then over to the "Mitersaw"
Wood Gas Machine tool Machine Lumber


Instead of cutting right on the end of that 4' long plank, I came back 12" and made a cut…easier to hold things still..Then came back and cut the bad end off..
Wood Table Hardwood Automotive tire Flooring


Goal was to get two sides at 12" long, and 2 ends at 6" long…
Wood Building Composite material Gas Urban design


There was a problem, though….these are 5-1/2" wide/tall….plan calls for 4" tall ones…hmmm. Set up the rip fence…
Wood Table Gas Tool Machine


First cut was a tad wide, on purpose..
Wood Rectangle Composite material Gas Hardwood


Run all 4 boards through, then joint that edge…
Wood Bumper Gas Machine Automotive exterior


Then reset the fence to exactly 4" width, then run the jointed edges against the fence…Ready for some joinery work.
Font Rectangle Parallel Engineering Paper


According to both this plan, and his video….first off will be a rebate on each end of the 2 end pieces. 3/16" deep, by 1/2" wide ( thickness of the boards I am using…Paul uses 9/16") Lay out and knife a few lines, Set up the Stanley No. 71-1/2 to 3/16" depth, and mark the end grain. It also marked a stop line out on the edges….
Wood Gas Metal Hardwood Machine


So I know where to stop this cut. Then back to the bench vise…
Wood Tool Gas Hardwood Flooring


And a wide chisel to pop most of the waste off. Paul wants a "Planed" look, so..
Wood Gas Metalworking hand tool Tool Machine tool


Work towards the center from both edges….one done..repeat 3 more times…

On the plans, it calls out the spacings of the tails….first I nned to know which edge is "Top" or Bottom, and mark that on the inside face…then lay out a few lines
Rectangle Slope Parallel Font Handwriting


Checking against the plan….good idea to keep the plan nearby…to make sure I'm cut these right..
Wood Gas Mobile phone Art Flooring


These cuts do not go all the way down…as there is a curve/angled Baseline to stop at. Paul used a 11mm:1mm angle..I used the MK2 Eyeball….either way, a sliding bevel square was used…and also to mark the tails cut lines…

Font Handwriting Parallel Rectangle Diagram


I'll get to them grooves later…once the saw was done with these cuts…chisels to remove the waste, until..
Wood Hardwood Lumber Building material Grass


The little 1/2 Pin was sawn off..
Wood Tool Metalworking hand tool Hand tool Gas


One done? Great, now repeat for the other 3 ends…
Wood Tool Air gun Gas Hand tool


About this time, back was getting sore between the shoulder blades, and the back of the right knee was complaining…looked at the bench..
Hand tool Tool Wood Metalworking hand tool Gas


And decided it was quitting time. About 3 hours IN the shop…was just about enough fun for one day, besides, there was a cold Guinness Draught Stout waiting in the fridge..

Maybe Monday..if we are still snowed in, I might open the shop, and try my hand at those matching pins..
Font Engineering Parallel Schematic Rectangle


As I'll use these tail to lay out the curved parts. Outsides of the box are hand planed to that rounded shape, the dovetails have to match for a better look.

Stay tuned…
 

Attachments

#7 ·
Tails first?

Strange as that might seem, as I normally cut pins first. But, to make this come out right, I need to do tails first..

Need a few boards cut to size, first. Layout the cross cuts…


Bad end, large square to lay out a few cuts, then over to the "Mitersaw"


Instead of cutting right on the end of that 4' long plank, I came back 12" and made a cut…easier to hold things still..Then came back and cut the bad end off..


Goal was to get two sides at 12" long, and 2 ends at 6" long…


There was a problem, though….these are 5-1/2" wide/tall….plan calls for 4" tall ones…hmmm. Set up the rip fence…


First cut was a tad wide, on purpose..


Run all 4 boards through, then joint that edge…


Then reset the fence to exactly 4" width, then run the jointed edges against the fence…Ready for some joinery work.


According to both this plan, and his video….first off will be a rebate on each end of the 2 end pieces. 3/16" deep, by 1/2" wide ( thickness of the boards I am using…Paul uses 9/16") Lay out and knife a few lines, Set up the Stanley No. 71-1/2 to 3/16" depth, and mark the end grain. It also marked a stop line out on the edges….


So I know where to stop this cut. Then back to the bench vise…


And a wide chisel to pop most of the waste off. Paul wants a "Planed" look, so..


Work towards the center from both edges….one done..repeat 3 more times…

On the plans, it calls out the spacings of the tails….first I nned to know which edge is "Top" or Bottom, and mark that on the inside face…then lay out a few lines


Checking against the plan….good idea to keep the plan nearby…to make sure I'm cut these right..


These cuts do not go all the way down…as there is a curve/angled Baseline to stop at. Paul used a 11mm:1mm angle..I used the MK2 Eyeball….either way, a sliding bevel square was used…and also to mark the tails cut lines…



I'll get to them grooves later…once the saw was done with these cuts…chisels to remove the waste, until..


The little 1/2 Pin was sawn off..


One done? Great, now repeat for the other 3 ends…


About this time, back was getting sore between the shoulder blades, and the back of the right knee was complaining…looked at the bench..


And decided it was quitting time. About 3 hours IN the shop…was just about enough fun for one day, besides, there was a cold Guinness Draught Stout waiting in the fridge..

Maybe Monday..if we are still snowed in, I might open the shop, and try my hand at those matching pins..


As I'll use these tail to lay out the curved parts. Outsides of the box are hand planed to that rounded shape, the dovetails have to match for a better look.

Stay tuned…
Not sure how that title got changed..have edited it to where this Part 2 belongs. Getting ready to write up Part 3…shortly…stay tuned…
 

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#8 ·
Matching pins

According to the Paul Sellers Plan. Lay the tails onto the end of one of the sides, and trace around each tail.
Wood Flooring Rectangle Hardwood Gas


Also, decide which face will be the inside, and which edges will be either the Top, or the Bottom..and mark the side as such. Since this will be corner #1, I mark the parts that way…..so I won't try to attach End #1 to Side #3…

Pins use a knife line that simply goes straight across, but the thickness of the tails.
Font Handwriting Parallel Rectangle Diagram


Note the pins in the drawing. Saw leaving the lines ( or at least try to) as vertical as you can..
Wood Tool Stonemason's hammer Gas Hardwood


And stop right at the baselines..next…select a decent chisel, and do a bit of chopping on the outside face first
Wood Automotive tire Gas Fender Composite material


Just enough to stop any blow-outs, when you flip this over and chop from the inside face. Then, stand the piece up in the bench vise, pare inbetween the pins. You will also pare the middle 2 pins back a bit, try to leave the lines that angle across the edge of those pins…as they need to fit ( a little better than Corner #1 did)
Wood Crosscut saw Wood stain Plank Lumber


Dry fit, only….then repeat for #2…
Wood Rectangle Natural material Hardwood Composite material


Not sure what happened with #3….
Wood Rectangle Hardwood Wood stain Plank


Then #4 allowed the box to be dry fitted up
Wood Rectangle Gas Hardwood Composite material


Yep, that is corner #1 showing off..has a few nibs to clear out, for a better fit. The box came out square, though.

Cutting list calls for 2 panels at 5/8" thickness..one for the lid, and one for the bottom…Scrap bin produced ONE at 7/8" thickness…was enough to make the top panel..after I resawed it down a bit…got close to the 5/8", inside (sawn face) is a bit rough, yet…bandsaw trouble)...Trimmed to about the right size..
Wood Rectangle Wood stain Hardwood Table


As for a panel for the bottom of the box….I cut a 1/2" thick panel..
Wood Rectangle Hardwood Composite material Gas


That I'll just adapt to fit…
Product Handwriting Rectangle Sleeve Font


So, maybe later today ( after Lunch?) we have some grooves to plough….

Stay tuned…
 

Attachments

#9 ·
Matching pins

According to the Paul Sellers Plan. Lay the tails onto the end of one of the sides, and trace around each tail.
Wood Flooring Rectangle Hardwood Gas


Also, decide which face will be the inside, and which edges will be either the Top, or the Bottom..and mark the side as such. Since this will be corner #1, I mark the parts that way…..so I won't try to attach End #1 to Side #3…

Pins use a knife line that simply goes straight across, but the thickness of the tails.
Font Handwriting Parallel Rectangle Diagram


Note the pins in the drawing. Saw leaving the lines ( or at least try to) as vertical as you can..
Wood Tool Stonemason's hammer Gas Hardwood


And stop right at the baselines..next…select a decent chisel, and do a bit of chopping on the outside face first
Wood Automotive tire Gas Fender Composite material


Just enough to stop any blow-outs, when you flip this over and chop from the inside face. Then, stand the piece up in the bench vise, pare inbetween the pins. You will also pare the middle 2 pins back a bit, try to leave the lines that angle across the edge of those pins…as they need to fit ( a little better than Corner #1 did)
Wood Crosscut saw Wood stain Plank Lumber


Dry fit, only….then repeat for #2…
Wood Rectangle Natural material Hardwood Composite material


Not sure what happened with #3….
Wood Rectangle Hardwood Wood stain Plank


Then #4 allowed the box to be dry fitted up
Wood Rectangle Gas Hardwood Composite material


Yep, that is corner #1 showing off..has a few nibs to clear out, for a better fit. The box came out square, though.

Cutting list calls for 2 panels at 5/8" thickness..one for the lid, and one for the bottom…Scrap bin produced ONE at 7/8" thickness…was enough to make the top panel..after I resawed it down a bit…got close to the 5/8", inside (sawn face) is a bit rough, yet…bandsaw trouble)...Trimmed to about the right size..
Wood Rectangle Wood stain Hardwood Table


As for a panel for the bottom of the box….I cut a 1/2" thick panel..
Wood Rectangle Hardwood Composite material Gas


That I'll just adapt to fit…
Product Handwriting Rectangle Sleeve Font


So, maybe later today ( after Lunch?) we have some grooves to plough….

Stay tuned…
Looking good, even with the challenges brought on by the curvy sides.
 

Attachments

#10 ·
Feeling Groovy...

Had a lot of tasks to do, today…and, after just over 2 hours, I had about half of them done…

Task #1: cut grooves into all four edges of both panels…
Wood Natural material Hardwood Composite material Rectangle


Easier said than done, but, there they are….
Wood Engineering Auto part Gear Automotive wheel system


Set up the Stanley 45 with a No.11 (3/16") cutter….can't use the sliding skate…just the main skate and the fence. Trying to center the groove in the 5/8" thick panel for the lid..was able to run a groove along both long grain edges, but was having trouble with the end grain cuts…we have ways
Wood Hardwood Plank Machine tool Wood stain


Meet the Groove Adjuster. Got the end grain grooves done…set aside the lid's panel..needed to work on the box's bottom panel…since it is 1/2" thick, and not 5/8"....some adjusting was needed…45 will have to sit this one out..

Took about 3 settings to get a centered groove….finally.

Task #2 Groove the top and bottom edges of all four sides…45 was still on the bench,,did a small jig to hold things still..
Wood Gas Engineering Motor vehicle Metal


Depth of this groove is 3/16"..same as that rebate on the ends…test fits…
Wood Floor Gas Flooring Automotive tire


Fits into the groove, but, bottoms out too soon…work on that later,,,need more grooves,,,
Wood Gas Machine Hardwood Machine tool


Like into the long sides…again the lid panel would fit the groove, but would bottom out too soon…hmmm..
Handwriting Rectangle Font Material property Parallel


Ah, that's why..back over the "Adjuster" remove the excess Oak…then try a dry fit of everything so far..
Wood Rectangle Gas Table Hardwood


And, the panel fits…great, now knock this apart, and reset for the bottom panel..
Saw Wood Calipers Flooring Hardwood


Things were a bit thinner…groove closer to the bottom edge…test fits as I went….got time for the dry fit assembly….....no-go…panel was about 1/8" too long…."Adjust to fix that….trial and error does work…but..
Table Rectangle Wood Gas Composite material


Still a tad too long? all 4 sides fit together….can always go back and trim a bit off the ends, maybe

About 2 hours so far…was getting sore…mainly behind the right knee….back was just starting to hurt, too..figured I would just sweep up all the Krunchies..
Automotive tire Hood Road surface Wood Automotive exterior


And call it a day. Maybe tomorrow, I can chop 2 stopped dados for a divider, plane the radius on each side of the box..one side at a time….clamp the box up, and saw and pare the proud dovetails down flush with the curve sides

Then I'll be ready to watch Episode #3 and see what is next…..I'm still on Episode #2 at the moment..

Stay tuned…
 

Attachments

#11 ·
Feeling Groovy...

Had a lot of tasks to do, today…and, after just over 2 hours, I had about half of them done…

Task #1: cut grooves into all four edges of both panels…
Wood Natural material Hardwood Composite material Rectangle


Easier said than done, but, there they are….
Wood Engineering Auto part Gear Automotive wheel system


Set up the Stanley 45 with a No.11 (3/16") cutter….can't use the sliding skate…just the main skate and the fence. Trying to center the groove in the 5/8" thick panel for the lid..was able to run a groove along both long grain edges, but was having trouble with the end grain cuts…we have ways
Wood Hardwood Plank Machine tool Wood stain


Meet the Groove Adjuster. Got the end grain grooves done…set aside the lid's panel..needed to work on the box's bottom panel…since it is 1/2" thick, and not 5/8"....some adjusting was needed…45 will have to sit this one out..

Took about 3 settings to get a centered groove….finally.

Task #2 Groove the top and bottom edges of all four sides…45 was still on the bench,,did a small jig to hold things still..
Wood Gas Engineering Motor vehicle Metal


Depth of this groove is 3/16"..same as that rebate on the ends…test fits…
Wood Floor Gas Flooring Automotive tire


Fits into the groove, but, bottoms out too soon…work on that later,,,need more grooves,,,
Wood Gas Machine Hardwood Machine tool


Like into the long sides…again the lid panel would fit the groove, but would bottom out too soon…hmmm..
Handwriting Rectangle Font Material property Parallel


Ah, that's why..back over the "Adjuster" remove the excess Oak…then try a dry fit of everything so far..
Wood Rectangle Gas Table Hardwood


And, the panel fits…great, now knock this apart, and reset for the bottom panel..
Saw Wood Calipers Flooring Hardwood


Things were a bit thinner…groove closer to the bottom edge…test fits as I went….got time for the dry fit assembly….....no-go…panel was about 1/8" too long…."Adjust to fix that….trial and error does work…but..
Table Rectangle Wood Gas Composite material


Still a tad too long? all 4 sides fit together….can always go back and trim a bit off the ends, maybe

About 2 hours so far…was getting sore…mainly behind the right knee….back was just starting to hurt, too..figured I would just sweep up all the Krunchies..
Automotive tire Hood Road surface Wood Automotive exterior


And call it a day. Maybe tomorrow, I can chop 2 stopped dados for a divider, plane the radius on each side of the box..one side at a time….clamp the box up, and saw and pare the proud dovetails down flush with the curve sides

Then I'll be ready to watch Episode #3 and see what is next…..I'm still on Episode #2 at the moment..

Stay tuned…
Interesting joint for the floating panels, but it looks like you've got it.
 

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#13 ·
Dados and curves..

Still working through all the tasks for Episode #2 of Paul Sellers Class…need a make a 3/8" thin divider so I can then chop 2 stopped dados to house said divider…except..I don't HAVE any stock AT 3/8" thick…hmmm..
Wood Flooring Hardwood Gas Rectangle


What I do have is some more of that 1/2" thick Red Oak….cut out a length about what I thought I would need. back over to the dry fitted box, figured out how wide the divider needed to be,,,marked that…back to the tablesaw…a quick rip cut..done, right? Still the matter of the extra 1/8" thickness….reset the saw..
Table Rectangle Wood Wood stain Flooring


And run this through twice…clean up the saw marks…we have a divider. Back to the bench…
Wood Rectangle Gas Flooring Composite material


And use the divider to layout 2 stopped dados…because the dados stop at the cut line for sawing off the lid…
Hand tool Saw Wood Metalworking hand tool Tool


Chisels and the router plane…3/8" wide by about 1/8" deep…just enough to hold the divider in place in the box, yet allow it to be removed, IF need be..one done..reset..
Wood Table Gas Lumber Composite material

Didn't take all that long, and I got to sit down doing this…test fit?
Wood Automotive tire Bumper Rim Auto part


Ok, that task is done..next?

The sides are planed into a radius on the outside…
Rectangle Slope Parallel Font Handwriting

Need a jig made to hold things still, while a smooth plane work them over…
Wood Composite material Gas Engineering Metal


Since I had just finished up with the ends, might as well start there…I set a combo square to 3/16"...set the square to the groove side of the board..and draw a "Stop Line"..
Wood Water Bumper Gas Automotive exterior


I work my way towards the centertrying to hit the stop line, yet have a smooth, gentle curve..using my hand to check for "flat spots"...one edge done, rotate the board and repeat…soon had both ends done..clamped them up to check how the curves came out..
Wood Bumper Motor vehicle Gas Hand tool


Not much of a curve, just enough. Then the long sides were next..
Wood Motor vehicle Lumber Hardwood Landscape


Used this plane again, plus the WR #62 as it had a longer sole…got the 2 long sides done…tried a dry fit
Wood Gas Plank Composite material Hardwood


With a clamp and the top panel in place…panel was having issues…correct the fit of one end groove..
Wood Automotive tire Gas Composite material Tool


Thinking this will be a Royal PITA to clamp up for a glue up…the tails and pins run a bit "wild" we have ways…
Automotive tire Wood Rectangle Gas Composite material


Left circle=before..right circle the aftermath….

made a big mess on the floor today..
Automotive tire Road surface Asphalt Wood Floor


Lots of shavings. Leg was getting sore, back was complaining a bit….3 hours of work…
Furniture Table Wood Rectangle Plant


And this was the result. Have to leave either the bottom panel out, or the lid panel…else I can't tear this down to get a glue up done…
All Tasks from Episode #2 are now done…waiting to see what Paul Sellers does for #3…

Stay tuned…
 

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#14 ·
a glue up done, a lid sawn free

What is it about glue-ups…that make the stress levels go so high…?

Anyway, first had a dry fit or 2 to do..he also wanted some edges rounded over…mainly the top and bottom panels.

Plane and sand paper for that. Then the "fun" could begin…I don't have the bar clamps like Paul uses…I have either pipe clamps or F style clamps….He cut his cauls in a curve….mine are thinner….fighting with clamps. Cheapo brush to spread the glue around….and..
Wood Hand tool Composite material Gas Metalworking hand tool


Let this sit overnight….

Today, after Brunch…went to the shop and removed that forest of clamps..
Wood Plant Gas Trunk Wood stain


Hmmm..will take a plane and a sander to clean this up…
Wood Gas Composite material Artifact Rectangle


Almost done…had to do all 4 sides…wipe this down..and lay out the cut lines..
Wood Rectangle Composite material Tints and shades Wood stain


Trying to center on that tail….all the way around…a few dots, then a straightedge to connect them all…
Automotive tire Wood Grey Chair Automotive exterior


All done? Ok, I have an old Disston No. 4 backsaw, 14" long, it's 9 ppi filed rip…Nice comfy handle….going to get a work out…the saw AND me..

With the box at that angle, saw into each corner first….just enough to guide the rest of the cuts,,do all 4 corners..
Then start with an end, and saw across..
Wood Household hardware Gas Composite material Hardwood


At this point, STOP. Turn the box over and repeat on the other end….then saw a side to connect the cuts on the ends…you might want to keep the box as high in the vise as you can…
Wood Composite material Natural material Hardwood Metal


Otherwise, you will get pinched…then cut the other side the same way…and this is what you will have..
Wood Window Rectangle Table Composite material


At this point, you can also open up the ends of the dado that will house the center divider….

Saw cuts will need some plane work…to level out any and all high spots…
Wood Machine tool Gas Machine Auto part


Once both the box and lid have been leveled, keep checking for any leftover spots that are too high..
Wood Rectangle Natural material Gas Hardwood


Like that left corner….so that when the lid is closed, you will not see the cut line, and the grain matches up..

1300 hrs..time to stop for today. All tasks from Episode #3 are done. Need to go and watch Episode #4, next.

Stay tuned…
 

Attachments

#15 ·
a glue up done, a lid sawn free

What is it about glue-ups…that make the stress levels go so high…?

Anyway, first had a dry fit or 2 to do..he also wanted some edges rounded over…mainly the top and bottom panels.

Plane and sand paper for that. Then the "fun" could begin…I don't have the bar clamps like Paul uses…I have either pipe clamps or F style clamps….He cut his cauls in a curve….mine are thinner….fighting with clamps. Cheapo brush to spread the glue around….and..
Wood Hand tool Composite material Gas Metalworking hand tool


Let this sit overnight….

Today, after Brunch…went to the shop and removed that forest of clamps..
Wood Plant Gas Trunk Wood stain


Hmmm..will take a plane and a sander to clean this up…
Wood Gas Composite material Artifact Rectangle


Almost done…had to do all 4 sides…wipe this down..and lay out the cut lines..
Wood Rectangle Composite material Tints and shades Wood stain


Trying to center on that tail….all the way around…a few dots, then a straightedge to connect them all…
Automotive tire Wood Grey Chair Automotive exterior


All done? Ok, I have an old Disston No. 4 backsaw, 14" long, it's 9 ppi filed rip…Nice comfy handle….going to get a work out…the saw AND me..

With the box at that angle, saw into each corner first….just enough to guide the rest of the cuts,,do all 4 corners..
Then start with an end, and saw across..
Wood Household hardware Gas Composite material Hardwood


At this point, STOP. Turn the box over and repeat on the other end….then saw a side to connect the cuts on the ends…you might want to keep the box as high in the vise as you can…
Wood Composite material Natural material Hardwood Metal


Otherwise, you will get pinched…then cut the other side the same way…and this is what you will have..
Wood Window Rectangle Table Composite material


At this point, you can also open up the ends of the dado that will house the center divider….

Saw cuts will need some plane work…to level out any and all high spots…
Wood Machine tool Gas Machine Auto part


Once both the box and lid have been leveled, keep checking for any leftover spots that are too high..
Wood Rectangle Natural material Gas Hardwood


Like that left corner….so that when the lid is closed, you will not see the cut line, and the grain matches up..

1300 hrs..time to stop for today. All tasks from Episode #3 are done. Need to go and watch Episode #4, next.

Stay tuned…
You are on track.
Looks good.
 

Attachments

#17 ·
A crash, a recovery, hinges installed...

Trying to get to the end of Episode #4, and MAYBE a start on Episode #5….
While I did have that dado opened up for the divider..
Rectangle Wood Tints and shades Glass Linens

There was still some hand plane work to do…Still had some high spots..was planing those down..when the lid flipped off the bench (and me?) and hit the concrete floor 34" down….with predictable results…so…
Wood Gas Office ruler Hardwood Cylinder


Re-glue the lid back together, and even squared it up, too….Took out my frustrations on a pair of chisels…
Gas Cylinder Wood Metal Engineering


Sharpened back up. I also had gone out that day, and bought a set of hinges..
Stairs Wood Tints and shades Font Triangle


And a quart of Shellac..
Ingredient Food Drink Cuisine Wood

Figured I'd give the glue about 8 hours to dry….2200 hrs that night…we got busy..
Wood Gas Hardwood Lumber Automotive wheel system


Got the lid out of the 2 clamps, got rid of a high corner so the lid would at least close up..
Wood Rectangle Gas Hardwood Natural material


Best I can do…Rounded up a few tools to be ready to install the hinges..like a Cordless drill for pilot holes..
Motor vehicle Steering wheel Wood Hand tool Rim


Had the box and lid in the bench vise…last minute sanding going on..
Bumper Wood Automotive exterior Rectangle Composite material


Got around to the back…Paul Sellers uses a trick to lay out hinge locations on a box..
Wood Finger Office supplies Art Paint


Set the hing on an end, mark across both the lid and the box…one line…both ends laid out, set the box aside..
Wood Composite material Gas Engineering Plank


Mortise to the depth of the leaf's thickness….not really very deep. Drill the pilot holes for two screws..
Foundry Wood Automotive wheel system Automotive tire Gas


Add the waxed up screws..and continue with the other hinge…
Wood Gas Engineering Flooring Concrete


Set the lid aside, bring the box back to the bench..using the marks, lay out the mortises to match the ones on the lid…same as before, shallow mortise, pilot holes for the waxed screws (yes, you will NEED to wax the threads)

Box into the bench vise, raised up to chop a Finger Lift…
Gas Transparency Metal Wood Glass


Gouge, 4-in-hand file, and some sandpaper….then set the box so that it is flush with the lid sitting on the bench..
Wood Gas Tool Rectangle Machine


Pilot holes, waxed threads…connect the lid to the box…check for fit..
Table Wood Rectangle Wood stain Flooring


There IS a gap round back from the hinges, will correct that later…fine tune this fit…also midnight? Time flies when you are having fun. Call it a night.

Still had to do a set of feet….final sanding….look for a short bit of chain to hold the lid…and find that dang Church Key, so I can open the can of shellac….

Stay tuned….
 

Attachments

#18 ·
A crash, a recovery, hinges installed...

Trying to get to the end of Episode #4, and MAYBE a start on Episode #5….
While I did have that dado opened up for the divider..
Rectangle Wood Tints and shades Glass Linens

There was still some hand plane work to do…Still had some high spots..was planing those down..when the lid flipped off the bench (and me?) and hit the concrete floor 34" down….with predictable results…so…
Wood Gas Office ruler Hardwood Cylinder


Re-glue the lid back together, and even squared it up, too….Took out my frustrations on a pair of chisels…
Gas Cylinder Wood Metal Engineering


Sharpened back up. I also had gone out that day, and bought a set of hinges..
Stairs Wood Tints and shades Font Triangle


And a quart of Shellac..
Ingredient Food Drink Cuisine Wood

Figured I'd give the glue about 8 hours to dry….2200 hrs that night…we got busy..
Wood Gas Hardwood Lumber Automotive wheel system


Got the lid out of the 2 clamps, got rid of a high corner so the lid would at least close up..
Wood Rectangle Gas Hardwood Natural material


Best I can do…Rounded up a few tools to be ready to install the hinges..like a Cordless drill for pilot holes..
Motor vehicle Steering wheel Wood Hand tool Rim


Had the box and lid in the bench vise…last minute sanding going on..
Bumper Wood Automotive exterior Rectangle Composite material


Got around to the back…Paul Sellers uses a trick to lay out hinge locations on a box..
Wood Finger Office supplies Art Paint


Set the hing on an end, mark across both the lid and the box…one line…both ends laid out, set the box aside..
Wood Composite material Gas Engineering Plank


Mortise to the depth of the leaf's thickness….not really very deep. Drill the pilot holes for two screws..
Foundry Wood Automotive wheel system Automotive tire Gas


Add the waxed up screws..and continue with the other hinge…
Wood Gas Engineering Flooring Concrete


Set the lid aside, bring the box back to the bench..using the marks, lay out the mortises to match the ones on the lid…same as before, shallow mortise, pilot holes for the waxed screws (yes, you will NEED to wax the threads)

Box into the bench vise, raised up to chop a Finger Lift…
Gas Transparency Metal Wood Glass


Gouge, 4-in-hand file, and some sandpaper….then set the box so that it is flush with the lid sitting on the bench..
Wood Gas Tool Rectangle Machine


Pilot holes, waxed threads…connect the lid to the box…check for fit..
Table Wood Rectangle Wood stain Flooring


There IS a gap round back from the hinges, will correct that later…fine tune this fit…also midnight? Time flies when you are having fun. Call it a night.

Still had to do a set of feet….final sanding….look for a short bit of chain to hold the lid…and find that dang Church Key, so I can open the can of shellac….

Stay tuned….
Coming together, and the lid doesn't look too much worse for the wear.
 

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