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Project: Business card holders #1: First project after a long break

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Blog entry by jamsomito posted 12-01-2019 07:54 PM 244 reads 0 times favorited 0 comments Add to Favorites Watch
no previous part Part 1 of Project: Business card holders series Part 2: building an army »

For Christmas last year, I made these amazing “coffee boxes:” https://www.lumberjocks.com/projects/407436

Those were my favorite project to date. But, woah, did I seriously underestimate the time it would take. I vowed to make something simpler as gifts this year. Then we had a 3rd kid unexpectedly and I vowed to make this years Christmas gifts even simpler yet. So, I decided to make these business card holders and cell phone stands. Two rectangles with a slot in them. Can’t get much easier than that! lol

The above is a prototype I made out of a scrap 2×6. This is one of the first projects I just started cutting in the shop as opposed to drawing everything up in Sketchup or something similar first. It was a little out of my comfort zone due to the chance of making more waste, but it was a lot more fun.

I got a new Freud Thin Kerf Rip blade for this project. A flat grind blade has been on my list for a long while for joinery purposes. I always found a good sharp general purpose blade does big rips very well. I’m never throwing my lumber through the blade anyway. So the actual designed purpose of this blade for ripping was a nice plus, but not the primary decision maker for me. This blade is a gnarly looking thing.

For this project I’m using some “reclaimed” oak… The office space above where I work was doing a remodel and I snagged some of the trim they tore out from the dumpster It’s nice quality red oak. Being trim, it was all about a half inch thick. I figured it would make a perfect medium for my office gifts as the company is energy/sustainability focused.

Anyway, I tested the rip blade with a resaw on this trim. It did alright. Still got some burning, felt about the same as a sharp general purpose blade. But I’m happy with it.

Since I couldn’t get the blade high enough for a single pass, I wound up with a ridge on my resawed parts. It could have been my blade was off of 90, though I doubt it was too far off, or it could simply be my wood was slightly cupped. I don’t own a jointer, which I’m guessing is what would have fixed the problem. I also don’t have a planer, which would have been a better way of thicknessing this stock.

So, off to the sander. I figured it would be easier to sand the boards whole as opposed to after I cut them into the leg and back pieces of the stands. I grabbed some “saved” sandpaper and went to work. An hour later I barely got through 2 boards and I wasn’t exactly happy with how it looked after sanding. I put on a new piece of paper and what a difference! Learned my lesson there… I made a pact with myself to throw away way more sandpaper this coming year. It just doesn’t “cut” after a certain point, and ain’t nobody got time for that!

And that’s as far as I got. Next up will be setting up a stop on the crosscut sled to make each of the pices. I set up the widths so every cut will be the same from here on out. Then stack them up to make the slots, a light hand- sanding, and we’re done!

In true myself fashion, I think I want to complicate it a bit more. I want to make each assembled piece sand on three pionts because this pine has warped a little. The oak will likely do the same over time. With 3 legs it will be stable regardless. To do this I think I’ll cut a shallow arc into the bottom of the front and back. It’ll be a quick job on the bandsaw or spindle sander, but I think it’ll be worth it.

I also think I’m going to do an acetone toner transfer from a laser print to put some company logos on the backs of all of these. From what I’ve seen and heard, it should also be an easy way to add a bit of personality and personalization to the gifts.

‘Till next time!



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