Interior Layout Poker-chip divider

Card divider Dice tray 145_{⁄8 in.} 135_{⁄8 in.} 8 in. 213_{⁄16 in.} 41_{⁄16 in.} 13_{⁄8 in.} 47_{⁄8 in.} 7 in. 7_{⁄8 in.} 1_{⁄2 in.} 1_{⁄2 in.} 1_{⁄4 in.} 1_{⁄4 in.} 1_{⁄2 in.} 1_{⁄2 in.}

3.

Raise the tablesaw blade to 3_{⁄16 in. and set the} fence 1_{⁄4 in. from the blade. This setup will produce} a 1_{⁄4-in.-wide raised lip along both edges of the dice} trays. Use a push stick to push the dice tray past the blade. Then rotate the tray, placing the oppo- site edge against the fence, and make another pass over the blade. Reset the fence to 3_{⁄8 in. and make} two more cuts, rotating the tray in between. Repeat moving the fence and making cuts until a groove is formed along the length of the tray. Repeat the pre- vious steps to cut the groove into the second dice tray (photo B ).

4.

Sand all the edges and surfaces of the trays and dividers with a sanding block and 150-grit sandpaper.

5.

Brush glue onto the edge-lap joints cut in the card dividers and onto the rabbeted ends of the dice trays. Slide the parts together and clamp. Let the glue dry for two hours before removing the clamps.

6.

To make the three poker-chip dividers, install a 3_{⁄4-in.-radius cove bit in the router table to rout} a radius into both sides of each divider. Cut the profiles in three or four progressively deeper cuts (photo c ). Trying to cut the 3⁄4-in.-radius cove in a single pass can cause chipping. Sand the poker- chip dividers smooth with 150-grit sandpaper. Then use the miter saw to trim the three dividers to their finished length of 43_{⁄4 in.}

7.

Install all the dividers and trays, and fill the box with the poker chips, cards, and dice. Check to be sure all components fit. Then empty the box and remove hinges before applying the finish.

8.

Lightly sand the entire box with 150-grit sand- paper. Blow off the sanding dust with compressed air and wipe down all surfaces with a clean, dry rag. Then, following the instructions on p. 36, apply a clear topcoat finish to the box.

cUt a 7_{⁄8-in.-wide gRoove along the length of}

each dice tray.

B

RoUt a RadiUs into both sides of each of the three poker-chip dividers. (It’s safer to rout one piece 16 in. long and then cut to the finished size.)

c

make the 13_{⁄8-in.-wide cUtoUts into the center}

of each card divider. These cutouts will straddle the ends of the dice trays.

eauty and func- tion come together per- fectly in this artist sketch box, which features an intricate banding composed of solid walnut and curly maple hardwood. The box top is cut at an angle, so when it’s opened, there’s a sloped surface for placing a sketchpad. A remov- able interior panel provides space for storing pads and paper, and the upper tray holds pencils, erasers, and other supplies. A handle and two latches make it easy to lock the box and carry it from place to place.

B

Artist

Sketch Box

Accented with two contrasting woods—curly maple and walnut— the center panels of the box are made of richly figured Karelian burl veneer. The burl panels are bordered

by quartered cherry and solid walnut trim on all corners. The walnut trim adds style and visual interest, but it also protects the cherry veneer from any bumps and knocks.

materials

Quantity Part Size conStruction

noteS

2 Box parts 3_{⁄4 in.  5}1_{⁄2 in.  32 in. curly maple}

1 Top 5_{⁄8 in.  11 in.  14 in. maple plywood}

1 Bottom 1_{⁄2 in.  10}1_{⁄4 in.  13}1_{⁄4 in. maple plywood}

1 Splines 5_{⁄16 in. } 1_{⁄2 in.  24 in. walnut}

1 Pencil-tray front 3_{⁄4 in.  1}9_{⁄16 in.  12}3_{⁄4 in. curly maple}

1 Pencil-tray bottom 5_{⁄16 in.  2}3_{⁄8 in.  13}1_{⁄4 in. curly maple}

1 Decorative banding 1_{⁄4 in.  2 in.  30 in. curly maple}

2 Decorative banding 1_{⁄16 in.  2 in.  30 in. walnut}

1 Flitch 1_{⁄42 in.  14 in.  84 in. Karelian burl veneer}

(for decorative panels) 1 Flitch 1_{⁄42 in.  6 in.  84 in. quartered cherry veneer}

(for decorative borders) 7 Corner banding (pieces) 5_{⁄32 in. } 5_{⁄32 in.  30 in. walnut}

1 Fixed interior panel 1_{⁄2 in.  10}1_{⁄8 in.  12}1_{⁄2 in. maple plywood}

1 Removable interior panel 1_{⁄2 in.  7}5_{⁄8 in.  12}1_{⁄2 in. maple plywood}

4 Panel edge trim 1_{⁄8 in. } 5_{⁄8 in.  30 in. walnut}

1 Cleat 3_{⁄8 in.  1}9_{⁄16 in.  12}3_{⁄4 in. curly maple}

1 Support block 3_{⁄4 in.  1}1_{⁄4 in.  12}3_{⁄4 in. any hardwood}

1 Support block 3_{⁄4 in. } 1_{⁄4 in.  12}3_{⁄4 in. any hardwood}

1 pair Hinges 3_{⁄4 in.  1 in. nickel finish}

1 pair Swing catches 11_{⁄8 in.  1}1_{⁄4 in. nickel finish}

3.

Cut the box top from 5_{⁄8-in.-thick maple ply-} wood, making it 11 in. wide by 14 in. long. The top must be 5_{⁄8 in. thick to equal the thickness of the} curly maple box parts. Now cut the box bottom from 1_{⁄2-in.-thick maple plywood; make it 10}1_{⁄4 in.} wide by 131_{⁄4 in. long.}

1.

Start by cutting two pieces of curly maple hard- wood to 3_{⁄4 in. thick by 5}1_{⁄2 in. wide by 32 in. long.} Plane both pieces to 5_{⁄8 in. thick, and then rip them} on the tablesaw to 51_{⁄8 in. wide (photo A ).}

2.

Crosscut each board to produce one 13-in.-long piece and one 16-in.-long piece. These four pieces are slightly longer than needed but will eventually form the front, back, and ends of the box. Making these box parts longer at this stage makes it easier to mill them to their finished dimensions later.

Cut the hardwood and

In document Making Wooden Boxes (Page 65-69)