Weekend Projects - Decorative Box archive
Friday 15 August 2014
Andy Standing uses scraps to make this attractive boxError loading Partial View script (file: ~/Views/MacroPartials/cwsGalleryImages.cshtml)
When faced with a pile of short but thick offcuts you might think that the best place for them would be the woodburner, but actually these pieces are ideal for boxmaking. You will need a bandsaw to re-saw them into thinner sections and some clamps for making up wider panels. However, with a few scraps and a little imagination, it is surprising what you can come up with.
STEP 1A pile of offcuts; these are ideal for boxmaking.
STEP 2Start the project by planing an accurate face...
STEP 3... and edge. This will make it much easier to re-saw the timber.
STEP 4Using a bandsaw, re-saw the offcuts into thinner sections. After each cut return the offcut to the planer and true up the face before taking the next cut.
STEP 5Once your boards are cut and sanded, rip them to width.
STEP 6The box is to be jointed with mitres strengthened with biscuits, so tilt your tablesaw to 45° and cut the four boards to length.
STEP 7The base of the box is a piece of 4mm thick ply, but any sheet material will do. It is to sit in a rebate so fit your router table with a rebate, or straight cutter and, using a small piece of the base board, set the cutter projection to its thickness. The height of the cutter should be two-thirds of the thickness of the side.
STEP 8Machine the rebate on the bottom edge of all four boards.
STEP 9Mark the positions for the biscuits in the centre of each board. One size '0' biscuit is used for each joint.
STEP 10Now you can carefully cut the joints for the box.
STEP 11Apply some glue to each joint and the biscuit slots.
STEP 12Assemble the box and clamp it up in a frame clamp, or a pair, if necessary. Check that the diagonal measurements are equal to ensure that the box is square.
STEP 13To make up a board for the top of the project, you may need to joint two narrower pieces. Use a butt joint and clamp up tight until the glue has cured.
STEP 14Clean up the board with a random orbit sander.
STEP 15Now you can trim the top of the box to size.
STEP 16To decorate the box I am going to inlay some 1.5mm stained boxwood (Buxus sempervirens) lines.
STEP 17To inlay a 1.5mm line on the top you need a 1.5mm diameter router cutter.
STEP 18For this design simply set the side fence on the router 30mm from the cutter. There is no need to mark out the top.
STEP 19To set the precise cutting depth to suit the line, firstly put the router on a flat surface and plunge the cutter so that it is just touching the surface. Now take a piece of the inlay line and place it on the top of the depth setting turret. Wind the setting rod down so that it sandwiches the inlay and lock the setting. Release the router, remove the line and you have set the precise depth for the cut.
STEP 20It can be a little tricky routing on a small box top with a tiny cutter. You have to hold the router by its base and its fence to make sure that it does not tip when it gets to the edge of the board or wander off line. Keep the bit plunged at all times.
It is worth practising on a scrap board first.