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Project by Troy posted 01-24-2010 02:57 AM 2892 views 19 times favorited 26 comments Add to Favorites Watch

This one is figured maple left over from my retirement display case with walnut legs and lid piece. I had to make a sled to dado the legs into the miters. I took a couple macro shots so you can see how the legs fit as well as some pretty extreme closeups of the grain.

Finished it with dye, then shellac, then water-based gloss seal.

-- Troy Bouffard || Master Sergeant, US Army (Retired) ||

26 comments so far

View richgreer's profile


4541 posts in 3525 days

#1 posted 01-24-2010 03:04 AM

Excellent! This is what quality box making is all about.

-- Rich, Cedar Rapids, IA - I'm a woodworker. I don't create beauty, I reveal it.

View DraftsmanRick's profile


112 posts in 3510 days

#2 posted 01-24-2010 03:12 AM

Very nice design! Nice choice of woods too.

-- Jesus was a carpenter

View SgtSnafu's profile


960 posts in 3722 days

#3 posted 01-24-2010 03:17 AM

I really like the design too – Well done…

Thanks for sharing

-- Scotty - aka... SgtSnafu - Randleman NC

View a1Jim's profile


117689 posts in 4027 days

#4 posted 01-24-2010 03:33 AM

Super box and great design

View jayjay's profile


639 posts in 3496 days

#5 posted 01-24-2010 03:49 AM


-- ~Jason~ , Albuquerque NM

View Triumph1's profile


930 posts in 3530 days

#6 posted 01-24-2010 03:55 AM

Beautifil Box! You did an amazing job on dado’ing the legs in…the macro shots just prove how much an amazing job!

-- Jeff , Wisconsin Please...can I stay in the basement a little longer, please!

View eddy's profile


939 posts in 3815 days

#7 posted 01-24-2010 03:55 AM

i like the way the legs are attached. but i can’t figure out what the cut looks like or how they are attached ?

-- self proclaimed copycat

View WistysWoodWorkingWonders's profile


12785 posts in 3607 days

#8 posted 01-24-2010 04:34 AM

Great job on a great looking box..

-- New Project = New Tool... it's just the way it is, don't fight it... :)

View knackonwood's profile


45 posts in 3891 days

#9 posted 01-24-2010 04:56 AM

wonderful design, beautiful work

View majeagle1's profile


1426 posts in 3946 days

#10 posted 01-24-2010 07:16 AM

Beautiful box and superb desing work….......... absolutely love it !!!!
Super tight joinery, really nice…..........

Don’t remember if I formally welcomed you to LJ’s, but if not, here is a GREAT BIG welcome.

You are a wonderful craftsman and designer, can’t wait for additional projects!

BTW, I hope you would take it as a compliment if I did a take off of your leg design of this box….....
Just how did you attach them anyway? Cutoff the corner and butt joiint? spline? ???/

-- Gene, Majestic Eagle Woodworks,,

View Troy's profile


186 posts in 3514 days

#11 posted 01-24-2010 07:46 AM

Thanks for the great comments; humbling for sure.
The way I made the legs was not too complicated. The most difficult part was making the sled, although not difficult, more time consuming, but now I gotta sled. The sled is just like my, and many others, spline sled. This simply allows the worker to dado a mitered joint.
Instead, imagine the bed part that holds the box to be turned 90 degrees counterclockwise. (I’ll post a pic of this sled soon). The only issue is that because dado blades typically stack from left-to-right (or vice-versa), you gotta decide on a width and stick to it. That’s the only way it stays centered, unless you want to incorporate waste material spacers and such. Mine is 1/2” dead-on and I am happy with that, seeing as most of my boxes use between 5/8 – 3/4” stock, half inch thick legs look good.
That’s it gang, just dado’d miters, nothing more; fully recessed. For the legs, just sneak up on the exact thickness in a planer; when in doubt, leave a touch and hand sand if necessary. Just be VERY careful with those fine edges until the legs are in place; any damage, no matter how small, will be noticeable. A bit of flush sanding will likely minimize/remove any tiny imperfections.
I should warn you that the dado in each mitered corner joint was 5/8” I believe, and I was surprised how much my Freud dado stack labored through this on my 3hp Delta Unisaw. You definitely need support in the back. There will likely be a bit of tear-out on the back end. Trim a blade width off all around on the table saw, usually have to anyhow for bandsaw’d lids.
Hope this helps. Thanks again.

-- Troy Bouffard || Master Sergeant, US Army (Retired) ||

View majeagle1's profile


1426 posts in 3946 days

#12 posted 01-24-2010 08:16 AM

Thanks Troy, pretty guttsy dado if I don’t say so myself….......

Doesn’t leave you much “mitered joint of the box” left while you are doing the dado on the other corners. Would seem to be a little fragile!

Did I read it right, the dado was 5/8” deep and 1/2” wide?

I wonder if a router table would do this as well ??? what do you think?

-- Gene, Majestic Eagle Woodworks,,

View Troy's profile


186 posts in 3514 days

#13 posted 01-24-2010 08:25 AM

Gene, you read right, it’s 5/8” deep, 1/2” wide. I suppose a router table may very well be worth a try, although it will likely require just as sturdy a sled/support system. Tear out can be taken care of easily also. As long as the box is 100% locked down and doesn’t move while routing, I am sure that would work fine. That method has all the requirements; a solid cutting and consistent blade/bit and an ultra-flat cut.

-- Troy Bouffard || Master Sergeant, US Army (Retired) ||

View OutPutter's profile


1199 posts in 4440 days

#14 posted 01-24-2010 11:37 AM

Very fine piece of work. I love the close up shots.

-- Jim

View webwood's profile


626 posts in 3700 days

#15 posted 01-24-2010 02:02 PM

nice job – love that maple

-- -erik & christy-

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