Maple Box Project, a start up

[steven c newman]

Thought maybe a break from all those "What plane should I buy?" Infomercials.....and maybe something a bit different to do...
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Had to use a 1/4" blade..as the 1/2" one..
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Had been badly beat up. Had a few scraps to resaw..
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Mainly Maple, and a bit of Ash...change of pace from the Pine of late...
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Trying for 3/8" thick parts.....resaw was coming out a bit wavy and brown....
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Tried a #5 cambered jack....was just too big....
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That recently cleaned up Stanley No. 3c seemed to do the job....both on the faces..
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And jointing an edge, or two.
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Set aside a book-matched pair...will glue these up for a panel for a lid. may have to add a bit, depends on what size the lid turns out to be.

Single Brain Cell Sketch Up is still working out the details....
Reset the bandsaw....
More on that....in the next episode..stay tuned..:rolleyes:

[steven c newman]

Ok, no chuting board needed, nor a shooting plane....we have other ways to get a square end to a board..
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zero deflection in use. Had a couple pieces needing trimmed square. Works for me.
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Ganged a bunch up, and jointed the edges, so all of these match each other...
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Bandsaw has been reset, to cut 1" wide strips....
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From these scraps...making a Frame & Panel Mini Chest/box.
With all the plane work, getting the thin boards flattened, and smooth..
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Made a big mess in the shop, today. Have until next Monday evening, to get this project done....Have other things needing worked on after that...like the Olde Ticker...

Stay tuned...

[steven c newman]

Bunch of parts...some ripped to 1-1/2" wide..
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And others to 1" wide, for the end frames..
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Added a strip in-between the two matched parts....and a forest of clamps.....this is a ROYAL PITA to try to glue up, and clamp.....c clamps holding a pair of cauls at each end. Yes, those are REAL c clamps.
Found a few other thin boards....may add them to the mix for the four sides...
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Might be a bit of Cherry? Have that Pine 1x laying on the bench, so I can beat on things, if need be...
That is enough for one day....stay tuned..

[steven c newman]

Today was Grocery Day....maybe after Supper, I can get back to woodworking? Making a Maple flavoured version of this little box..
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That was framed in Walnut, with Cherry raised panels. Lid was all Walnut.
Will get some measurements after a bit, and see how they match up to what lumber I have milled up...
We'll see how this goes...

[steven c newman]

Ok, measurements are done...will have to adjust them to the stock I have..
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A cut list of sorts said I needed a few 1-1/2" wide items..
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4, to be exact. They also needed to be 8-1/2" long....give or take a hair...
Also needed 4 pc @ 1" wide, by the same length,,
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Then things got interesting....needed 4 pc @ 1-1/8 wide....by 3/4" thick ( to match the others) by 12-1/2".......stock was only 11-3/4" long...OK, design change...
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had two pieces that just needed resawn and jointed for width, thickness was ok....the other two were way too thick..needed a bit ripped off, then planed smooth to 3/4" thick
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Since these 4 were a bit longer....I used the Millers Falls No. 11 instead of the Stanley #3c.
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Was starting to get worn out....made quite a mess on the floor, too...
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Laid out 8 out of the 12 parts milled, so far..
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Hmmm, one slight problem...
Besides not enough space for photos...BRB..

[steven c newman]

Well, got the front and back frame pieces cut to size, I think..
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May keep these as the front frame...and..
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These as the back frame. Still need to mill a few parts for the ends.

The "problem"?
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While I COULD use this panel...I only have one of these...and it is Cherry. The ones I wanted to use?
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Are a tad too short.....then I remembered...Tenons! I can adjust those down a bit until the short stuff is no longer short...
Was enough fun for one day....maybe tomorrow I can get something done?
Stay tuned....

[Dan Hulbert]

Really enjoy your design on the fly approach. I've used it many times when using only materials on hand. Not to mention correcting the occasional oops.

[steven c newman]

Ooops? Oooops? Who...me?:rolleyes:

Reset the Stanley 45....was still set up as a dado plane....had to retract the spurs....reset the skates, and fence..
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I had grooves to mill...
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I had to trim the ends square.....
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About the best way to do that....had a lot of grooves to do....both for the raised panels to sit in....and a bottom panel

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Ends will join the front and back via a Tongue & groove joint....needed a groove for that made...
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And needed feet profiles milled...
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Then worked on tenons...to fir the raised panels ( that I am now gluing up)
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Langdon 75 mitre box to do the shoulder cuts.....bandsaw to do the cheek cuts.....and cut a haunched tenon...
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Planed the edges on the panel parts....then glued a matched pair....need to let this sit awhile ( while I move the yard.....yuck)
IF I get rested up...I may set up for chopping mortises...we'll see

Stay tuned..

[steven c newman]

Snuck back down to the shop for a bit....meh. One glue up out of the clamps..another right back into them...

Four mortises have now been chopped....frame for the back of the box is ready for a raised panel....then a glue up ( beginning to hate glue ups...) depending on yard sales tomorrow, I MIGHT get something else done....we'll see. Will need to size a panel to fit into the frames...and give them a bevel edge.

[steven c newman]

"Let the Midnight Special, shine a light on me.."

One panel out of the clamps
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Second panel right back into the clamps...
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Dry fit done, since the mortises for this frame are done..
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So I could size the first panel a little better..
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Trimmed, and the sawn edge jointed...panel was also planed flat...
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With a Stanley No. 3c. Will see what happens later this morning....
Stay tuned......

[Stew Denton]

Hi Steven,

The matchled grain on your panel is going to really look good finished up.

Stew

[steven c newman]

Paying the price of all that work, yesterday...including mowing the yard.....Uncle Charles ( Horse) is in the toes and the back of the legs, today.....may take the day off.

[steven c newman]

One Mountain Dew & Tonic done....decided to try the shop....
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Second panel is out of the clamps. Decided to make it a raised panel....ala Paul Sellers
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End grain was done first...fitted to the corner posts, too..
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The edges were done next....Panel is for the back of the box.....put things together, with some glue and clamps..
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And set it aside....got the first panel also raised..and set aside, while I chop a few mortises (4)
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Then more glue and clamps..
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And the front is all glued up....which leaves the end frames to be built, next..
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At least I have the four corner posts ready to go....maybe tomorrow, I can get something done?
Stay tuned...

[steven c newman]

Wasn't a great day in the shop....some things went decently enough...
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Front and back frames are out of the clamps.....ganged them up, to match them up.....couple spots needed planed..meh..
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The four corner posts for the end panels.....squared up, cut to final length....then planed so they matched each other...
had issues with one of them...with using the tongue cutter..
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Grooves were fine...it did not like this cut...wound up in the trashcan. Made a new part to replace it....the other three behaved after that...
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Why the tongue?
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So when I glue the four sides together, this will line things up...did a bit of drawing, too...
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And made the cut..
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Used this as a pattern for the other three.
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Got the rails cut to length...had a bit of plane work to get all four to match each other..
Next episode.....stay tuned

[steven c newman]

Ok, got the Stanley 45 reset back to groove cutter mode..
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Used it a few times...
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And then cut some stubby tenons..
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Worked over a couple panels to raise them...
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Then glue and clamps..
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One end is done..
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And then the other end. Let these sit, until tomorrow....while I decide whether to mill a groove all the way across to house the box's bottom panel....or..not...
Stay tuned.....

[steven c newman]

Well...no groove across the bottom edge....would have been a rebate, anyway,,,,notched the plywood to fit..
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had a forest of clamps spring up in the shop..
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Will let this sit a day..or three....then clean up all the joints.
Laid out the parts for a lid..
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Once the box is cleaned up, I can size the lid to fit. Thinking there MAY be some brass corner trim plates added. We'll see how it goes...

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Maybe something like these?
Stay tuned

[steven c newman]

Trying to correct a few "issues" with this box...
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Added a caul, to pull the ends into alignment....
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Undercover clamp?
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Added a strip of Maple, to correct a mis-alignment issuse,,,,not sure whether it was the tongue or the groove that was out of line....
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Not a whole lot of room left on the bench....may check things later today and see IF the clamps can be removed.
Spider bite on the left arm.....they didn't like me broom taking down all their webs....not sure if it was a small white spider, or a tiny black one....left a nasty hole, and me of blood thinners to boot..
Errands to run this morning..might be late this afternoon, before I can get to the "spider den", er..shop.
Stay tuned...might even make SDI Hartmann blush.....

[steven c newman]

Wasn't much cussing, today. Got the box out of the clamps ( and it didn't fly apart...) and started to clean the corners up...
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Plane, and a couple sanders were used....even some hand sanding :eek:
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All corners got done, a few spots were fixed...dusted this thing off.
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Amber Shellac as a seal coat...
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Back didn't look too bad..
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Nor did the front....laid out parts to make a lid...
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Need to plane the panel flat, and then make it a Raised Panel...then cut a groove to house it.
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Need to cut this one in exactly half, to make the ends of the lid. After that....we'll see how it turns out, first....as to what details will get done to it.
Stay tuned...

[steven c newman]

Ok...after a decent rest...I went back to the shop....Panel was planed flat, on both faces. Chose the best looking of the two, and raised the panel. #3c did all the panel raising....Millers Falls No. 14 flattened the panel.

Long stiles (?) were jointed straight. Then face planed until they were straight along that way. Mitre box to cut the third in to two equal parts...Stanley 45 to mill a groove in all four parts, to house the raised panel.

Stubby tenons were milled onto the short rails (?)....then glue and a couple clamps...
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Will sit flush with the back of the box, with a bit of overhang on the other sides...
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Wanted to get the lid at least built today....not sure when I will be allowed back in the shop....
Stay tuned...

[Stew Denton]

Hi Steven,

The box is starting to look very good, and it looks like you are making rapid progress, but take care of the ticker.

Stew

[steven c newman]

Lab work and scans are done...go back there in the morning for the Ablation thing....

The T.E.E. Scan left me with a sore throat...and very "loopy".....No shop time tonight....Wasn't even allowed to drive home, needed a "Designated Driver" for that...
CT Scan, with contrast after that other scan....

About all I CAN do right now...is sit and bug you all on the computer.....

[steven c newman]

Back home again....shop is closed for about the next two weeks.....letting the vein heal up....

Before I left for the place yesterday morning....I brought the box, the lid...a couple brass hinges, the screws, and push drill for pilot holes...and the screwdriver needed...upstairs, where I could install the hinges, at least.....
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A look at the front of the box....
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Lid still needs a coat of Amber Shellac....
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An idea of the hinge size. VERY tiny screws.

Letting a hole in a vein where the top of the leg is, heal up.....Still very sore today....spent the night over there...0400 they came in and changed the dressing. Was a LONG night...

[Stew Denton]

Hi Steven,

The box is looking good, and it sounds like you are on the bend....good news all the way around.

Stew

[steven c newman]

Hinges are installed, now.
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Yankee push drill, with the smallest bit it had....out of the 6 in the handle..to drill a few pilot holes..
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Because the screws are kind of small..
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Needed a very small, Phillips screwdriver, too...Installed the hinges on the lid, first...then onto the box it went.....then these holes..
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Thinking about adding a handle on each end....
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Centered right in the panel...one of these?
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Also looking at something for the lid to be opened with...
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Whether to set one of these here..or...out on the front of the edge?

Shellac, a brush, and the Poly Gloss have also been brought up. Had to send a "runner" down the steps, as I am not allowed. Even brought up a tool tray..
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As it had the black screws for the handles...
Will see how things go...

[steven c newman]

Handles are chosen, and installed....and a coat of Amber Shellac applied where needed...
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Lid has a handle..
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Both ends have a handle, as well..
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Open the lid...
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May or may not get a short chain to hold the lid.
Needs buffed out, before the gloss poly goes on. Haven't decided about anything on the inside...not much I can do, right now.
Stay tuned....almost done.

[steven c newman]

Box has been lightly sanded to 220 grit, and wiped down. Now, IF I can find that "good" ( Purdy) brush....I might be able to get a coat of clear gloss on it....

Not really feeling all that great, today.....still too sore to do a whole lot of moving around. Debating on whether to varnish the inside of the box....

When done, it will sit over on the Maple Chest of drawers I built....as the wood figure seems to match each other....other than the Walnut trim ( didn't have enough Walnut scraps for the box)
Maybe rub the varnish down later,,,and see how it looks. Have a bit of black chain to attach to the lid....will see about how to attach that.

May be one more post to this long winded episode...be a few weeks before any other projects get started...stay tuned.

[steven c newman]

OK, found the brush! No, it is not a Purdy. :mad:...something called SHUR-LINE. 1-1/2" wide trim brush. Bummer #2? Nothing in the house to clean the poly off, once I am done with the varnish....doubt IF a cup of gas from the mower would work:eek:...

Tired and sore, today...may wait a day, before the varnish goes on. trying not to get too carried away, and mess me up.

[steven c newman]

To do the varnish, tomorrow....I needed a way to hold the lid open, without it flopping backwards too far. So....got out a length of chain, and two of the smallest "Cup Hooks" I could find. Yankee #41 to drill a few pilot holes....first one didn't line up with the open area....cut the chain to a decently short length, add it to the hooks, and crimp the hooks closed. Put the toys away. That be the extent of the woodworking for today. Didn't even set the camera up....unless someone wants to see the results?

Stay tuned,.....
Edit to add:
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Chain installed...
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Hook details....and..where this little box will be going to...
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As the Maple grain seems to match....
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Tomorrow's job....

[steven c newman]

Letting the first coat of varnish dry....and see IF a second one would be needed...

[steven c newman]

Calling this one done....
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Have rubbed things out...
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Have added some pads for the feet..
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Seems a shame this side will be the back..
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Guess this was better than just burning the wood scraps. Stands 9" tall, lid is 9-1/4 x 14"

Thanks for following along.

[steven c newman]

Sometimes...I wonder how doing one of these build along projects would turn out...as a video....or something like Rough Cut. I do not have any way to "shoot" any video...so someone else would have to do that task. I may just stick to writing these up.

[Jason Martin Winnipeg]

Thanks, Steven. It was nice reading this project thread, and the box looks great.