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Thread: Poplar Box Project

  1. #1
    Join Date
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    Poplar Box Project

    About done with all the rehabs, need to start making saw dust, again
    Had a few "Project Boards"...of Poplar..I think..
    Storage boxes, start up.JPG
    Might be Pine....hauled these to the shop...picked out the best of the litter...needed one board cut in two equal pieces, and another that the grain was close to a match, was to be cut into 6" long ends....Couldn't get the tablesaw out, or, even my shop stool.
    Poplar Box Project, buried.JPG
    So, will have to go Olde School...for the cross cuts...
    Dungeon Saw til, mitre saw location 1.JPG
    Was one of the reasons this saw wound up here...to break down lumber to size. But, there was a problem....Saw felt...wobbly.. Got to looking, King bolt was loose, as was the knurled bolts holding the guides in place. Turned the frame over, torqued the bolts down, tight....saw is no longer a weeble
    Boards were NOT square on the ends...
    Poplar Box Project, not square.JPG
    Marked out for the center of the board, and ran that through the saw..
    Poplar Box Project, trim saw.JPG
    And..
    .Poplar Box Project, squared.JPG
    Set the two halves together, marked a second line, made a bit more saw dust..
    Poplar Box Project, making sawdust.JPG
    Until I had the 4 main parts cut...
    Poplar Box Project, 4 sides.JPG
    2 sides, and 2 ends....1/2 an hour of shop time's worth of work...part 2 will be about the rest of that hour...

    Stay tuned ( yes, another Build-along thread)

  2. #2
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    Part 2? Well, a box needs a bottom, and a panel for a lid...had some fancy plywood left over from the Desk Project...one panel turned out to be wide enough...and had enough length for two panels. Made the cuts on the mitre box..
    Poplar Box Project, plywood panels.JPG
    Will cut to final size, once I figure that out...
    Corner joints will be a Box/Finger Joint...Got the 2 sides lined up....needed a hair off a corner...
    Poplar Box Project, end grain plane.JPG
    That is the Stanley #3 i had just rehabbed. Layout tools were next..
    Poplar Box Project, lay out tools.JPG
    Since that is the chisel I'll be using to chop with, I use it to set the finger spacings...
    Poplar Box Project, joint laid out.JPG
    Waste was marked with that "dot", had the saw dug out, and about ready to do a bit of saw work..
    Poplar Box Project, Joinery saw.JPG
    Even got the shop stool dug out..
    Poplar Box Project, shop stool.JPG
    When I was informed I needed to drive the van to the stores...and take Grandson #3 to his job...
    Poplar Box Project, more lay out tools.JPG
    So, this will have to wait until the next "Shop Time" happens...
    PoplarBox Project, spacing jig.JPG
    Jig: what ever size chisel you intend to use, use it to set how the fingers are spaced out....and, work from both ens towards the middle. I have a wide finger there, as that is where the lid will get separated from the box...2 grooves from the Stanley 45, overlapped just enough. Gives the box a dust seal lid.

    Stay tuned...this is just the start...

  3. #3
    Looks like Poplar to me.
    Lee Schierer
    USNA- '71
    Captain USN(Ret)

    My advice, comments and suggestions are free, but it costs money to run the site. If you found something of value here please give a little something back by becoming a contributor! Please Contribute

  4. #4
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    I will say this....do NOT go into Hobby Lobby on payday.....can be very painful to the wallet....

    All day road trip....maybe after supper, I can make a bit of sawdust...?

  5. #5
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    Will show off the Hobby Lobby loot, later.
    Spent a bit of time in the shop after supper...
    Poplar Box Project, gang sawing.JPG
    Ganged the 2 sides together, and ran a saw for a while....I added a spring clamp under the vise...
    Poplar Box Project, spring clamped.JPG
    To keep the two boards together, when I flip them end for end...set up the shop stool, and lowered the ganged up boards to about 1/4" above the bench's top...and sat down...
    Poplar Box Project, sitting down on the job.JPG
    Handsome fella, ain't he?
    Poplar Box Project, hand sawing.JPG
    Saw guide. Got both ends sawn..
    Poplar Box Project, both ends done.JPG
    All markings go to the inside of the box, the outsides?
    Poplar Box Project, outside faces.JPG
    Have to keep things laid out the way they were sawn...marked the insides..
    Poplar Box Project, insides marked.JPG
    Top...Bottom....INside, and a number for each corner...set one of these aside, for now, and set up to do some chopping..
    Poplar Box Project, chopping station.JPG
    Good thing I planed that piece of Ash flat....note the "hammer" I used?
    Part 2 of this evening's follies coming right up..

  6. #6
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    Ok, Part 2...chop about 1/2 way down, leave a bit out on the ends..
    Poplar Box Project, halfway.JPG
    This is the outside face of the board...flip the board over, and chop the rest of the waste out
    Poplar Box Project, end done.JPG
    Then use these fingers to lay out the matching ones on a end piece...saw, leaving as much of the lines as you can, on the waste side of the line, then chop out the waste..
    Poplar Box Project, chisel work.JPG
    use the same chisel I laid out the other fingers with..then try a dry fit...
    Poplar Box Project, 1st dry fit.JPG
    Not too hateful...first ones are always the worst....the rest are usually a lot better...
    Set up the 45...
    Poplar Box Project, groove cutter.JPG
    As each side gets 3 grooves.
    Poplar Box Project, Stanley 45.JPG
    Top and bottom panels sit in a groove....then there is 2 more grooves, inside and outside of the lid.
    Poplar Box Project, tool set.JPG
    Hobby Lobby...Needed a small Phillips screwdriver...as the screws are going to be a bit tiny..
    Poplar Box Project, hardware 3.JPG
    Stay tuned...

  7. #7
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    Ok, 3 hours in the shop, this afternoon...got all the corners done...
    Poplar Box Project, 4 corners done.JPG
    Unfolded to get ready for a few grooves..
    Poplar Box Project, unfolded.JPG
    Set up a jig, and got the Stanley 45 set up...
    Poplar Box Project, first groove.JPG
    Grooves for the top and bottom panels...but, to do the groove to split off the lid with...I needed to change to rods on the Stanley 45..
    Poplar Box Project, reset rods.JPG
    Short rods wouldn't reach far enough...reset the jig a bit...and made some noodles...
    Poplar Box Project, making noodles.JPG
    A rub with a plain old candle helps things slide better..
    Poplar Box Project, lid groove.JPG
    Then cut the plywood panels to size...length and width...then a test fit..
    Poplar Box Project, assembled.JPG
    Then a dry run with the clamps....
    Poplar Box Project, dry run clamps.JPG
    No glue, yet....will need a few cauls made. I marked where the outside groove will go, and set up the Stanley 45. Once the box is glued up, and the clamps come off, they I can run the stanley 45 again...and split off the lid.

    Stay tuned...the cussing is about to start..

  8. #8
    Join Date
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    Hammond, Indiana
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    Nice.
    Very nice.

  9. #9
    Most of my projects are boxes, of one sort or another. I can’t wait to see what this one is for.

  10. #10
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    I need to go buy some poplar.

    It may be popular to use poplar.

  11. #11
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    Clamps came off, cauls cut to size...glue applied...clamps back on....will let the mess sit a day....added one extra clamp.....needed 3 hands...only had 2.....and a LOT of cussing, and a hammer to "adjust" the cauls & clamps....

    Try holding 2 cauls and tightening a clamp...at the same time...with just 2 hands.....tain't fun

    Film @ 2300 hrs....

  12. #12
    Quote Originally Posted by steven c newman View Post
    Clamps came off, cauls cut to size...glue applied...clamps back on....will let the mess sit a day....added one extra clamp.....needed 3 hands...only had 2.....and a LOT of cussing, and a hammer to "adjust" the cauls & clamps....

    Try holding 2 cauls and tightening a clamp...at the same time...with just 2 hands.....tain't fun

    Film @ 2300 hrs....
    i use popsicle sticks and blue tape to make a caul. Blue tape is almost as useful as a third arm.

  13. #13
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    Too much flex....
    Poplar Box Project, glued up 1.JPG
    Prefer stiffer ones for cauls..

  14. #14
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    Clamps and cauls came off this morning....clamped the box in the vise...
    Poplar Box Project, out of the clamps.JPG
    And ready for a bit of clean up..
    Poplar Box Project, cleaned up.JPG
    Got all 4 sides cleaned up, then made a jig, to hold things still, long enough to run a groove..
    Poplar Box Project, groove starts.JPG
    Along the long sides...
    Poplar Box Project, long groove.JPG
    A wee deep? Then clamped the box into the vise, and groove the ends...
    Poplar Box Project, short grooves.JPG
    Then run a marking gauge around, and a knife...to split the lid off...test fits showed the inner lid was a bit too wide..so
    Poplar Box Project, Lip adjuster.JPG
    Reset the Stanley 45 a bit,,,and adjusted the lip...
    Poplar Box Project, front view.JPG
    Lid now fits the way it is supposed to...
    Poplar Box Project, open the lid.JPG
    All that is left to do, is the hardware, and a finish..of some sort...
    Stay tuned

  15. #15
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    May try to do the hinges and a latch after supper? At least until my eyes get crossed....

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