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

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