wood joinery box
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Table of Contents
IntroductionThe ProcessLegend / AbbreviationsDimensioned Drawings
Wedge / Shim JigCut Sheets / Materials ListReferences
Introduction
Fascinate your friends and family with this
elegant keepsake box held together with nothing
more than fine joinery. Designed as an entry for the
Lumberjocks.com Summer 2007 Woodworkers
Challenge, this Curly Maple Keepsake Box
accented with Walnut, Cocobolo and Kingwood will
test your joinery skills while creating that special
family heirloom. Measuring 6W x 5H x 9 5/8L t
small box can probably be built from shop scraps and
the price of a Starbucks Coffee
his
Difficulty:Average woodworking skills
Overall Dimensions:6 W by 9 5/8 L by 5 H
Materials cost (As shown):$15+
Hours to complete:15+
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The Process
I started by machining all the required pieces to
final dimensions. This included re-sawing and
surfacing the top piece of curly maple to 3/8
and creating a sliding dovetail with a dovetail
bit. Next I surfaced the bottom to 3/8 as well,
drilled the holes for the feet, turned the feet,
created the wedges ( see attached wedge Jig
documentation ) installed the feet and pared the
remaining material left above with a sharp
chisel. Its imperative that all handwork be
completed prior to assembly as it will be virtually
impossible to sand or chisel after the box hasbeen assembled. It should also be m
that careful attention should be paid to the
direction of the grain in relation to the
placement of the wedge! Essentially, the cut
and wedge should be perpendicular to the
grain both in the foot and the bottom piece of
the box. Failure to follow these steps may
lead to splitting of the foot, base or both.
entioned
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Once assembled, I finished sanded theentire box and separated the top fromthe bottom using the band saw
Once the top was removed the dados were cut in both the top and bottom portions of the box, thehinges machined to fit the dado, a hole was drilled for the 3/16 pin, and then the hinge wasinstalled and pinned with 1/8 dowel
Note:
Back portion of hinge isrounded in order to allow topfull movement.
The T-Slot cut, the 1/8 installed and Viola!
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Wedge / Shim Jig
Heres a handy little jig for making wedges shims alike. Simply find some scrapapproximately 6x12, cut a 3/8x8 wedge as shown in the photo below. Attach your choiceof handle and you are ready
Merely set your rip fence toallow the jig to pass freely andthen adjust to desired thicknessof shim tip. Setting the fencefurther away will result in athicker tip while setting thefence closer to the blade will
result in a paper thin tip.
The great part is now youhave a use for all thatextra scrap laying around
the shop
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Material ListRough Dimensions
Parts No L W T Material Sheets
Lumber
Top / Bottom 1 9 1/2 5 1/2 Curly Maple Front and Back 2 9 1/2 5 1/2 Soft Maple Sides 2 6 1/2 5 1/2 Soft Maple Legs 1 1 1 1/2 King Wood Hinges 2 1 1/4 1/2 1/4 Cocobolo Wedges 4 Walnut Pins 8 3 1/4" WalnutPins 4 1/8" Other
Total BF
Finishes
Arm R Seal 1 pt Shellac 1 pt
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http://www.generalfinishes.com/msds-data/GF-Arm-R-Seal_Data_Sheet-062905.pdfhttp://www.woodcraft.com/family.aspx?FamilyID=4210http://www.woodcraft.com/family.aspx?FamilyID=4210http://www.generalfinishes.com/msds-data/GF-Arm-R-Seal_Data_Sheet-062905.pdf -
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References
Applying the Finish with the Wood Whisperer Is this pod cast Marc covers the basics ofapplying the Seal - R - Cell finish
When Dovetails Cry - A dovetail video with The Wood Whisperer
Joinery Some basic joinery with Matts at Matts Basement Workshop
Dados Everything you ever wanted to know about dados
www.lumberjocks.com
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