woodplans online - keepsake box

7/30/2019 WoodPlans Online - Keepsake Box

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N

A B

G

C

A B

G

fi x 3 x 28" Birds-eye maple

fi x 2 x 28" Bubinga

x 6 x 12" Bubinga x 5 x 12" Birds-eye maple

I H

D

* * *

*

*

*

F F

*Plane to thickness listedin the Materials List.

cutting diagram

To have continuous grain flow at the corners of a box, miter-cut the pieces in

sequence from the blank (e.g., cut the back first followed by left side, front, and rightside). Identify the parts with numbers, where shown, to make it easy to match up thecorners during assembly.

Cut parts in sequence for continuous grain flow

SHOPTIP

43 1A

1 2 3 4Back

LeftSide

Front RightSide

B A B2

x 6 x 12" Hardwood plywood

E x 1 x 12" Bubinga

SplinesJ


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B

B

5 x 8" velvet

" groove" deep" from

bottom edge

x x 2fi" spline8"

5"

1fi"

" round-overs

G

I

6"

7"

" rabbet " deep

" round-overs

" round-over

" slot fi" deep

18 bevelG

I

No round-oversalong bottom edge

4 x 7" cardstock

"

E

A

D

Corners cut at 45

" groove " deep

F

F

F

J

D

C

C

H

CD

D

x x 2fi" spline

A

2"

4"

2"

2""

2fi"

1 EXPLODED VIEW

A B

"

"-wide blade tilted 45

Tablesaw

D

" groove

" deep

/C , /

1a SPLINE GROOVE DETAIL


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Part T W L Matl. Qty.

A* front and back " 2" 8" BM 2

B* sides " 2" 5" BM 2

C* front and back trim "

v 8"

B 4

D* side trim " " 5" B 4

E bottom " 4" 7" HP 1

F* feet " " 2" B 4

G* lid sides " 2" 7" BM 2

H* lid center " " 7" B 1

I* handle braces " 1" 1" B 2

J handle " fi" 6" B 1

*Parts initially cut oversize. See the instructions.

Materials Key: BMbirds-eye maple, Bbubinga, HPhardwood plywood.Supplies: Spray adhesive, velvet, cardstock.

Buying Guide

Hardwood kit. Enough stock for one box, kit no. W1431, $25.95 ppd.Enough stock for five boxes, kit no. W1435, $99.95 ppd. Specify woodcombination for kit (birds-eye maple/bubinga, lacewood/cocobolo, orash/cherry). Some blanks in kit are preglued and machined to simplifyproject. Order from Heritage Building Specialties, 205 N. Cascade St.,Fergus Falls, MN 56537, or call 800/524-4184.

F I N I S H E D S I Z E

You dont have to riskgetting your fingers tooclose to the moving blade ofyour tablesaw or bandsawto form tapers on smallparts like the feet (F). Asafe way to do this is tosand the tapers, and to usea 12"-long blank that will

keep your fingers out ofharms way. First, mount abelt sander in your vise,with the belt up. Then, formthe tapers on the end of theblank by sanding to thelines of the attachedpattern, as shown at right.

Forming tapers onsmall parts safely

SHOPTIP

materials list5On the inside face of the 228"blank, cut a " groove " deepand " from the bottom edge toreceive the bottom (E), whereshown on Drawing 1. Finish-sandthe grooved face of the blank to220 grit.6With your tablesaw blade tiltedto 45, miter-cut the glued-upblank to form the front and backpieces (A/C) and side pieces (B/D)to the lengths listed. (We cuttest s tock first to verify tightmiters.) Use a backer board toavoid chip-out.7Referring to Drawing 1a and toPhoto A for setup, cut a "groove " deep in the ends ofthe front and back pieces (A/C)and side pieces (B/D) to receive

the splines, where shown onDrawing 1. (We made test cuts inscrap first to verify the grooveposition and depth.)8Cut or sand away a small amountof material at a 45 angle at eachcorner of the bottom (E) to enableit to clear the splines during boxassembly. Then, dry-assemble the


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A

B

As shown above, use a

stopblock to ensure consistentpositioning of the splinegrooves in the mitered ends of

the box parts.

As shown at left, with the rabbetfacing up, rip a "-wide stripfrom the blank. This rabbeted

blank will form the feet (F).

front, back, and side pieces; thesplines; and the bottom, and checkthat all joints fit together withoutgaps. Remove material from thecorners of the bottom little by littleuntil all joints fit correctly.

9Apply glue to the mitered ends ofthe front, back, and side pieces,and in the spline grooves and "grooves in these pieces. Now,apply glue to the splines, andassemble the pieces with thebottom located in the " groove.Secure the box with a band clamp,and check for square.


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Now, do some footwork1From "-thick stock, cut a 412"blank to form the feet (F). A wideblank keeps hands well away fromthe tablesaw blade when rippingthe foot stock from the blank.2Cut a fi" rabbet fi" deep alongone edge of the blank.

3Rip a "-wide strip from therabbeted side of the blank, asshown in Photo B.4Make four photocopies of thefull-size foot pattern, Drawing 2.Using spray adhesive, attach thetapered foot part of the pattern toone end of the blank, bending itover the blank at the fold line.5Taper the sides of the foot bysanding to the pattern lines. (Seethe Shop Tip shown on page 5.)

Then, crosscut the 2"-long footfrom the blank.6 Using the remaining patterns andfollowing the same process, formthe other three feet from the blank.7To complete the feet, sand "round-overs on all outer edges ofthe feet, where shown on Drawing 1.8From a scrap of 1"-thick stock,make a 310" spacer block tosupport the box at the requiredheight for attaching the feet. Applyglue to the top 1" area on the inside

of the feet. With the box placed onthe spacer block, as shown inPhoto C, position the feet on thebox, and secure with a band clamp.

Put a lid on it1From "-thick stock, cut two28fi" pieces for the lid sides(G). As shown on the CuttingDiagram, cut these from a 5"-widepiece to maintain grain flowon the lid. Also, from "-thickstock, cut a 8fi" strip for the lid

center (H).2Glue and clamp the lid center (H)between the lid sides (G). After theglue is dry, trim the lid (G/H) to itsfinished length of 7".3To cut the 18 bevel on the lid,where shown on Drawing 3, tiltyour saw blade to 18 fromvertical, and position your fence fi"

away from the base of the blade,where shown on Drawing 3a. Cutthe bevel on the ends of the lidfirst; then, cut the sides. Cutting inthis sequence minimizes chip-out.4Using your tablesaw or arabbeting bit in your table-mountedrouter, cut a " rabbet " deeparound the perimeter of the lid(G/H) on the bottom side, where

shown on Drawing 3. To avoidchip-out, make several passesaround the lid, raising the blade orbit a little at a time with each pass.5 Sand the " round-over ont h e t o p o u t e r e d g e s o f t h el id (G/H) , where shown onDrawing 3. Finish-sand the entirelid to 220 grit.

6To make the handle braces (I),first cut a 112" blank from "-thick stock.7 Install a "-wide blade in yourtablesaw and set it to fi" high.Adjust your fence to center theblade on the " thickness of theblank. Now, cut a groove alongthe length of the blank to accept thehandle (J), where shown on the end

view of the full-size handle bracepattern, Drawing 4. Then, crosscutthe blank to make two 1"-longpieces.8Make two photocopies of thefull-size handle brace pattern.Attach the front view part of thepattern to the handle brace piecesusing spray adhesive. Sand to the

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C

With the box on a 1" spacer, make sure that all four feet touch the

work surface before tightening the band clamp.


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""

" round-overs TOP VIEW

fi" rabbet fi" deep

2"

FFold line

""

F

FRONTVIEW

SIDEVIEW

2 FOOT

FULL-SIZE

PATTERN

B

D

E

G

C

A

C D

J

I

" groove

" deep

1fi"

"

" round-over sanded

to shape

" rabbet" deep

2"

18

R="

"

"

"

"

F

5 x 8"velvet

"

"

4 x 7"

cardstock

" clearance all around

1" glue areaon insidefaces of feet

"

"

"

"

3 SECTION VIEW

To ensure full-sized patterns are correctsize, your printer should be set to print

at 100% (not fit to page). Measure full-sized patterns to verify size.

fi

1"

SCALE


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