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Project Information

Well I eventually finished my mates box for his camping kit air compressor.

Construction: Its all Plywood with 45deg joints all round including the top and base.

My test sample is sitting next to the clamps in picture 6.

Again I weaseled out of doing splines, sorry Big Al!

The material was all cut using a rip fence on the table saw,

Some timely words of advice, if you do it this way make sure there is zero gap between the rip fence and surface of the saw table when cutting the second 45 deg edge of the pieces as the angle may slip under the gap and create errors.

It takes a bit of care in setting the fence to ensure it is perfectly set at 90 to the blade or your box will go rhombus on you.

I used two sets if framing clamps to hold the edges together and square and the usual clamps to hold the top and base in place when doing the glue up.

Left everything to set overnight and then powered up the table saw again to partly slit the lid and base.
finished it by slitting open with a trimming knife.

I then gave everything a finishing sand, then applied the transfer image to the lid.
once it was finally ready it was a touch up with some 0000 steel wool and on with the final finishes.

Finish: Oil based clear satin finish

Hardware: Fitted a pair of Florentine hinges externally to the back and an almost matching catch to the front then added eight rubber feet, to the box, four to the base and another four to back with the hinges … thats a total of 40 toes!.... tee hee!

I used the packing from the original cardboard box as the internals.

All ready for the next camping trip.

Acknowledgements:

Big Al, Boxguy for the box construction Video post and

The CrafsMan and Knot Curser for the image transfer process.

Gallery

Comments

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3,142 Posts
Very FLASH.
Love the 45 Joints.

Bob
 

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5,593 Posts
That's one very neat box… I'm sorely tempted to have a go at box making!!
 

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Second go around turned out awesome Rob.

Thanks for the fence tip, I've been cutting my miters on my dewalt miter saw but plan on making a box miter cutting jig for my table saw so as not to have to tilt the blade, just haven't gotten around to it yet. Alan (BoxGuy) also uses a tablesaw jig and has made a blog on how to make one. The jig rides the miter slot on the table and tilts your work piece at a 45 to the blade.
 

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Rob, great job on this box. I especially like the bumpers and the decal. It is very nicely done. This technique means that no plywood edges will show.

Thanks for mentioning the video. Here is a link to the video. if others want to see it. Now if this box only had a few splines…

I have built boxes with the 45s all around like you have used in this construction. I found that using a 45 degree router bit mounted in a table gave me better results than using my table saw to angle the edges. It also lets the sharp edge of the cut run higher along the fence face, and I didn't have to fight keeping it from slipping under the fence.

This is a link to the jig for 45ing corners that Blackie mentioned.

Keep boxing and keep posting. Your work is always fun to see.
 

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Nicely done…impressive that you did miters on the table saw.
 

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great job rob im sure your friend is quite happy with the result on this.also thanks for the tip on the miter.
Second go around turned out awesome Rob.

Thanks for the fence tip, I ve been cutting my miters on my dewalt miter saw but plan on making a box miter cutting jig for my table saw so as not to have to tilt the blade, just haven t gotten around to it yet. Alan (BoxGuy) also uses a tablesaw jig and has made a blog on how to make one. The jig rides the miter slot on the table and tilts your work piece at a 45 to the blade.

- Blackie_
im thinking about making this jig that blackie mentions myself,seems the sharp edge of the miter always slides under the fence.
 

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Impressively done with all the 45's, Rob! Good tip about the mitered piece sliding under the fence. Thanks for sharing.
 

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Looks well made. I also like the look without splines on this one.
 

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Great idea, love the box
 

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Very COOL box!

One thing good about Plywood…
The edges are always a combination of grains…
as a result, one can glue plywood edges BUTT joints, Miter joints, etc. and NEVER have to worry about weak gue joints… They will always strong and NOT NEED SPLINES…

COOL Video too… full of good tips…

Thank you!
 

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Thanks guys and dolls for your interest and supporting comments Kiss kiss and hug hug , you know who gets what !! (I hope)
 
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