Wood 2 Box
Project
Intro
Skill Objectives
• Stock Preparation
– Jointer
– Surface Planer
– Table Saw
• Joinery
– Finger Joint
– Rabbet
– Dada
– Sliding Dovetail
Paper Work
Due Date: April 20th (4 weeks)
• Start Timesheet – 3/20 ‘Planning’
• Complete Bill of Materials
• Start Procedure Sheet
– Very Important because of the NUMBER
of Parts
Parts List
•
Three Parts List Tables on the Shop
Drawings
– Upper Right Hand Corner
1. Drawer Assembly Parts List
2. Box Assembly Parts List
3. Box Lid Assembly Parts List
1 BF = W x L x H/144
• ALL MEASUREMENTS MUST BE IN
INCHES
• W  WIDTH ACROSS THE GRAIN
– Always 1st Number
• L  LENGTH WITH THE GRAIN
– Always 2nd Number
• H  THICKNESS OF THE WOOD
– Always 3rd Number
– If there isn’t a 3rd Number it is ¾”
Board Feet
• You MUST use the ROUGH DIMENSION
when figuring COST
– You need 1” thick material to get ¼”, ½” or ¾”
thick stock
• Basic Rules of Thumb:
– Add ½” to the WIDTH
– Add 2” to the LENGTH
– Add ¼” to the THICKNESS
DEPENDS ON
CONDITION OF
LUMBER
Example
• Finished Dimension: 3 ¾” x 16” x ½”
• Rough Dimension: 4 ¼” x 18” x 1”
W X L X H/144
4.25” x 18” x 1”/144
76.5”/144
BF=.53125
WOOD = MAPLE
.53125 X $3.10 = $1.65
Remember
• Use ROUGH DIMENSIONS
• Double Check the NUMBER of
Parts
• Double Check you are using the
CORRECT price for the Wood
–You will have more than 1 wood
type
How Much $$$$$$$
Wood Available:
• Soft Maple  $3.10 bf
• Cherry  $4.90 bf
• Poplar  $2.85 bf
• Bubinga  $15.90 bf
• Red Oak  $3.20 bf
Wood 2 Box
Project
Day 2
-Stock Selection and Prep
Safety Tests
• You must have
passed the following
tests with a 100%
–
–
–
–
Jointer
Surface Planer
RAS
Sliding Compound
Miter Saw
Selecting Your Stock
• Wood is EXPENSIVE
• ASK, DOUBLE
CHECK, TRIPLE
CHECK BEFORE
YOU DO ANYTHING!
6” X 36”
6” X 20”
Available Wood
•
•
•
•
•
Soft Maple  $3.10 bf
Cherry  $4.90 bf
Poplar  $2.85 bf
Bubinga  $15.90 bf
Red Oak  $3.20 bf
Bill of Materials
• Bill of Materials
MUST be complete
• TOTAL
$COST$ IS
DUE TO
WHS
Jointing & Planing
1. Joint one FACE and one EDGE
2. Surface Plane to 5/8” THICK
STOP
3. Layout your Pieces on your Wood
1. Like a JIGSAW Puzzle (Best Use of Wood)
Ripping on Table Saw
1. Review your Layout with Mr. Thuman
2. Follow Instruction given (INDIVIDUAL):
1. RIP on Table Saw
2. Crosscut on SLIDING COMPOUND MITER
SAW
1. Remember to SQUARE UP ONE END!!!
YOU WILL BE LOSING POINTS FOR
MISTAKES!!
Cutting Accuracy & Time
• ACCURACY IS
IMPORTANT IF YOU
WANT YOUR BOX
TO LOOK GOOD!!!
• TAKE YOUR TIME
AND DO IT
CORRECTLY THE
1ST TIME!
Basic Geometry
IF YOU
WANT
A SQUARE
BOX
THIS SIDE
THIS SIDE
THIS SIDE
THIS SIDE
How Much $$$$$$$
Wood Available:
• Soft Maple  $3.10 bf
• Cherry  $4.90 bf
• Poplar  $2.85 bf
• Bubinga  $15.90 bf
• Red Oak  $3.20 bf
Wood 2 Box
Project
Day 3
-Ripping and Crosscutting Finished
DImensions
Safety Tests
•
•
•
•
•
•
•
Andrew Aberts
Tera Baker
Doug Blank
Paul Hassett
Chad Lawson
Billy Rittelmeyer
Mike Shafer
Finished Dimensions
• Cutting ALL of your pieces will be like a
JIGSAW puzzle
– Best USE of material
• I will review and give instructions to EACH
student BEFORE you start RIPPING or
CUTTING anything!!
– Reduces Mistakes and wasted MONEY
Joinery Layout
• Once ALL pieces are CUT to the EXACT
Finished Dimension
• Label EVERY Piece
– Name
– Best Face, Top, Bottom, Left, Right, etc.
• Begin Laying Out ALL joinery
– Rabbets, Dados, Grooves, etc
– Finger Joints, Sliding Dovetails
Procedure Form
• EVERYONE MUST complete the
Procedure Form
• Each Step needs to be SIGNED OFF by
Mr. Thuman
Questions!!??
Part Name & Quantity
Wood 2 Box
Project
Day 4 & 5
-Laying Out ALL Joints & Labeling ALL
Pieces
Joinery Layout
• Once ALL pieces are CUT to the EXACT
Finished Dimension
• Label EVERY Piece
– Name
– Best Face, Top, Bottom, Left, Right, etc.
• Begin Laying Out ALL joinery
– Rabbets, Dados, Grooves, etc
– Finger Joints, Sliding Dovetails
Missing Pieces?
• Make sure you have ALL your pieces
– See Mr. Thuman if you don’t
– Share between Students
Safety Tests
• Band Saw
• Belt/Disc Sander
• Portable Tools
Safety Tests
Unless you
have passed
ALL safety
tests with a
100% you will
not use any
tools
Wood 2 Box
Project
Day 6, 7 & 8
-Cutting Finger Joints
Objective
• Understand BASIC
concepts of Finger
Joint Layout
• Understand use of
Finger Joint JIG
• Cut Finger Joints
using Table Saw
Finger Joint
A finger joint or box combing or box joint
is a woodworking technique used to join
two pieces of wood at right angles to each
other. It is much like a dovetail joint except
that the pins are square and not angled
and usually equally spaced. The joint
relies on glue for holding together as it
does not have the mechanical strength of
a dovetail
Use and Benefits
• Case Joinery
• Drawers
• Anything that needs
to be joined at 90
degree angles
•
•
•
•
•
•
•
Strength
Simplicity
Decorative
Speed
Good in Compression
Good in Shear
Bad in Tension
Finger Joint Layout
• Equally Divide Width
of Work Piece into an
EVEN number of
Fingers
• Depth of Joint equals
Thickness of Work
Piece
• Width of Finger is
determined by
Strength or Aesthetic
Good and Bad
ALL
EQUAL
Sliding Jig
• Holds Stock Vertically
– To Mill End Grain
• Correctly Spaces
Finger Joints
• This one makes
ONLY ½” wide Finger
Joints
• Any stock used must
be EQUALLY
DIVIDABLE by ½”
Fence
Blade
Cover
Indexing Pin/Stop
Runners
Stop – prevents
cutting through entire
Jig
Use of Jig
First Cut –
Stock Against
INDEX PIN
Second Cut –
previous cut
fits over
INDEX PIN
Completed Joint
Questions
Ask
Now!
Wood 2 Box
Project
Day 9 & 10
-Cutting Sliding Dovetail
Sliding Dovetail
• Method of joining 2
pieces of wood at 90
degrees
• Creates a Structural
AND Mechanical
Connection
• Can only be pulled
apart in 1 direction
Tools Needed:
• Hollow Chisel
Mortiser
• Band Saw
• Chisel
• Square
• Hammer
1st Step
¾”
• Use HOLLOW
CHISEL MORTISER
to make a SQUARE
MORTISE across the
BACK face of the
DRAWER FRONT
• CENTERLINE of
MORTISE is ¾”
from EDGE
2nd Step
• Cut PIN on both
DRAWER SIDES
• Use Layout JIG for
SHOULDER MARK
• Use Layout JIG for
CHEEK Depth
3rd Step
• Use BANDSAW to cut
PIN
• Cut from Outside
Corner to CHEEK
DEPTH mark
4th Step
• Using PIN as guide,
trace the angles onto
DRAWER FACE
• Use a CHISEL and
SLOWLY angle the
cheeks of the square
mortise
5th Step
• Patience
• Take you TIME and go
SLOWLY
• You want it to be a SNUG fit
Questions
Ask
Now!
Wood 2 Box
Project
Day 11 & 12
-Cutting Rabbets, Dados & Grooves
Objective & Tools
• Correctly and Safely
cut the required
Dado, Rabbet and
Groove for the Finger
Joint Box Project
• Review Layout of
needed Joinery
•
•
•
•
•
Back Saw
Hammer
Chisel
Square
Bench Hook
• Table Saw
Drawer
Box Sides
Only
Drawer Side (x2)
• Completed AFTER Dovetail Pin
• Need a MATCHING PAIR (Opposite)
Dado: ¼” wide x 1/8” deep
¼”
Rabbet: ¼” wide x 1/8” deep
Box Bottom (x4)
• After Finger Joints are milled
Cannot go thru a Finger
Groove: ¼” wide x 5/16” deep
Demonstration
• I will demonstrate how to
SAFELY do these cuts on the
TABLE SAW and the using the
Back Saw AND Chisel on the
Drawer
Questions
Ask
Now!
Wood 2 Box
Project
Day 13
-Assembling Drawer
Materials Needed
• Sander (Dual Action)
• Sand Paper
– 80grit, 100grit, 120grit, 150grit
•
•
•
•
Bucket of Water AND Rag
Glue
Clamps
Index Cards for Shims
Procedure
1. Sand ALL INTERIOR surfaces of drawer
parts
2. Sand ALL surfaces that would be difficult
to sand when assembled
3. BE CAREFUL not to round over and
edges or ruin any of your Joinery
4. NEVER Sand any Joints or Surfaces that
will be hidden by a joint
Gluing & Clamping
1. Glue and Shim if needed the SIDES to
the FACE
1. Make sure they are SQUARE to FACE
2. Glue and Clamp BACK into DADOs
1. Make sure ENTIRE drawer is SQUARE
2. Measure Diagonals – need to be equal
3. Clean up Glue with Water
4. Measure and Fit BOTTOM Panel
Center-Line of Clamp
ALIGNED with CenterLine of Drawer Side
Make sure Shoulders
are TIGHT and Sides are
SQUARE
ALIGNED with CenterLine of Drawer Side
Make sure Shoulders
are TIGHT and Drawer is
SQUARE
Questions
Ask
Now!
Wood 2 Box
Project
Day 14
-Cutting Drawer Opening
Procedure
•
•
•
•
Select your BEST front/back bottom of box
Install in JIG on CNC machine
Run Program
Square up Opening or Round Corners of
Drawer Face to match opening
– Use a FILE or SANDPAPER on a Block of
Wood
Questions
Ask
Now!
Wood 2 Box
Project
Day 15 & 16
-Box Dry Assembly & Sanding
Procedure
• Make sure ALL parts are CUT to
FINISHED Dimensions
• Make sure ALL joinery is COMPLETE
– Groove for Bottom
– Rabbets
– Finger Joints
– Dado
• Carefully CLAMP ENTIRE box together
Check for Quality
• Everything is Square
– Measure Diagonals
– Use a Square
• Gaps or Cracks at Joints
• Top AND Bottom MATCH
• Adjust Finger Joints IF NEEDED
– File or Sand Paper WRAPPED around a Stick
• CAREFULLY take apart
Sand to 150grit
• Sand ALL
interior
Surfaces
–80grit
–100grit
–120grit
–150grit
Questions
Ask
Now!
Wood 2 Box
Project
Day 17
-Box Assembly
Materials
• Glue
• Bucket of Water and Rag
• AT LEAST 4 Clamps
– Maybe More
• Make sure you CLEAN UP ALL glue
Questions
Ask
Now!
Wood 2 Box
Project
Day 18 & 19
-Fitting Drawer
Objective
• Fit the drawer to the ASSEMBLED BOX so
that is slides smoothly
Material
• Glue
• Tape
• Pre-Made Runner – 9/16” x 9/16
– Softwood
• Bucket of Water
Glue Runners to Drawer Sides
•Runners SHOULD be slightly PROUD
•Plane to Fit Drawer Opening
Questions
Ask
Now!
Wood 2 Box
Project
Day 20
-Fitting Dividers and Bottom
Materials
• All Dividers NEED to be fitted AND Cut to
FINAL dimensions
– USE your BOX not the measurements on the
Plans
• Bucket of Water and Glue
• Tape or Thin Scrap Wood to use as
WEDGES
Procedure
Wood 2 Box
Project
Day 21
-Fitting Hardware
Wood 2 Box
Project
Day 22, 23 & 24
-Final Sanding and Finishing
Project Due Today
Last Day to Work IN Class
After School Work
Mon, Wed, Thurs, Fri  2:30 to 3:00
Tues  2:30 to 4:30
Unit Test
Tuesday May 1st
What’s On the Test?
• Stock Prep
– Four-Square
• Joinery
– Finger Joints,
Rabbet, Groove,
Dovetail
ALL Dado,
QUESTIONS
FROM
• Tool Use
WARM-UPS
– Jointer, Planer, Table Saw, Radial Arm Saw, Sliding
Compound Miter Saw
TEST IS
OPEN NOTE
• Measurement
– Adding and Dividing Fractions
– Reading a Ruler
– Reading a Machine Scale