Kerf Box

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Project by Jerbone posted 02-12-2014 05:18 PM 2188 views 1 time favorited 9 comments Add to Favorites Watch

I wanted to practice making a box with hidden splines so I grabbed some red oak scraps I had.

Following one of Doug Stowes book I created the sled for my router, which worked pretty darn well. However I ran into issues cutting the splines on the TS, since I do not have a band saw. Working with small pieces on the table saw is a skill I need to work on.
Anyway after the box was done, I had the idea to mimic the outside of the box to a building I saw in Chicago. So I set the blade on my table saw to 1/8th and cut a dado around the box, then moved the fence in 1/8th and cut again. It actually went rather quickly, being one of the only times I just used the tape measure built into the saw.
The top came off rather smoothly and fit well. Using the flip stick method I addded the hinges, and they went smoother than ever. The slight gap in the box was due to some slightly lager than needed screws holding hinges. I really need to find a good supplier of brass screws of all different sizes. I replaced them after the pics were taken and it sits perfectly flush now.
I finished it with my BLO and was carefull to use a card scrapper with a rag around it to remove the puddled BLO in the kerfs.

Thanks for Looking,


-- Joining two of my passions, beer and woodworking,

9 comments so far

View WoodGuyScott's profile


51 posts in 2470 days

#1 posted 02-12-2014 05:57 PM

Very neat. I always like seeing projects that are simple in process and striking in appearance. This definitely fits the bill.

-- --Shafe

View longgone's profile


5688 posts in 4115 days

#2 posted 02-12-2014 06:15 PM

The kerfs came out nice and a different look. Here is a great source for a variety of screws.

View steve_in_ohio's profile


1195 posts in 2417 days

#3 posted 02-12-2014 06:45 PM

very different design, great work

-- steve, simple and effective

View madts's profile


1941 posts in 3146 days

#4 posted 02-12-2014 07:02 PM

Nice box, came out very nice. Pray tell. What is the flip stick method?

-- Thor and Odin are still the greatest of Gods.

View Monte Pittman's profile

Monte Pittman

30560 posts in 3144 days

#5 posted 02-12-2014 08:36 PM

very cool

-- Nature created it, I just assemble it.

View Roger Gaborski's profile

Roger Gaborski

333 posts in 4554 days

#6 posted 02-12-2014 11:57 PM

Turned out very nice

-- Roger Gaborski,

View sgmdwk's profile


308 posts in 2679 days

#7 posted 02-13-2014 03:02 AM

Sweet little box. Well done.

-- Dave K.

View Jerbone's profile


35 posts in 2729 days

#8 posted 02-13-2014 02:25 PM

Wow, I appreciate the comments.

My wife had mentioned something similar about how it turned out so nice without following a complex process.

I plan on trying that site for some new brass screws, box stores have the worst.

Oh the flip stick method. My friend showed me a video he had of Doug Stowe building small boxes where it demonstrated very well. Here is a basic run down; sure there are others here that can explain it much better.

Take a scrap and cut it the exact length of your box. Then place your hinge on the scrap as to where you want to position the hinge. Now mark both edges of the hinge on your scrap “flip stick.” Now I use my table saw and nibble away at the space between the markings so when done the hinge slides into the slot with a snug fit. So now move to the router table and set your bit height to be half of your hinges. Place your stick on the table and push it against the bit. Now set a stop block on that side of the table, slide it the other way and then place another stop block. The fence needs to be set back the distance you want the hinge to sit on the side of the box. So take the box and lid and router out all the material it lets you within your stop blocks. Your hinge should now slide in snuggly between the box and its lid. Now flip your stick and setup the stop blocks again. Route the other side and you should be done with minimal chisel work.

I hope that gives you a basic idea of how it works. I can barely do, much less tell someone how at this point.

-- Joining two of my passions, beer and woodworking,

View Fishinbo's profile


11362 posts in 2982 days

#9 posted 02-18-2014 02:53 PM

Very nice box, awesome splines and like the clean lines. Great job!

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