| Blog series by ruddhess | updated 04-25-2015 04:28 PM | 5 parts | 10133 reads | 9 comments total |
Part 1: Number 2 - second toolbox.
I enjoyed making the first one so much, here goes number 2. I decided to leave the drywall screws in the batten boards on the top of the first box. I like the way they look, and I like the way they grip/hold stuff down. I’ve been using drywall screws to put stuff together for since forever. I think they look fine. Kind of utilitarian. That fits my style well. So I am going to use 1-1/4” DW screws for the flat joins and 2-1/2” DW screws for the perpendicular joins (bugle head...
Part 2: Cutting Mortises & Fitting Up
Marking out the mortises – shallow chisel cuts on outside edges and nail punch the center so forstner bit will center correctly. 3/4” Forstner bit works well. Chopping the corners out with a 3/4” chisel. Works well. Close-up of one mortise at the beginning cuts. Initial fit for the first set of mortises. Pictures of the mortise/tenon fit. Much better (less gaps) than the first box I made recently. Inside corner. Outside corner. One...
Part 3: Glue Up - Sides
Finished cutting the mortises and everything fit pretty well. Just had to run the rasp over a couple of the joints to level everything first. Then got the sides all glued up. Diagonal measurements are the same – square overall. This one is coming out better than the first one (so far). Just more pictures of each of the square mortise/tenons.
Part 4: Bottom Glue-up & Assembly
Got some more work done on my second box. Bottom piece glued-up and trimmed and attached with #8 X 2” drywall screws. Inside the box with bottom attached.
Part 5: The Top - Handles, End Caps, & Lid w/Battens
Handles attached. Fitting battens for the lid. The lid with battens attached with drywall screws. The lid has been glued and screwed and is resting on the end caps. This one is all done except for the diagonal batten. Diagonal batten fitting well. Top all finished!
