Wood 2 Box Project Intro

Skill Objectives Stock Preparation Joinery 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 Drawer Assembly Parts List Box Assembly Parts List 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

Day 2 -- Stock Selection and Prep 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

6” X 36” 6” X 20” 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

TOTAL $COST$ IS DUE TO WHS Bill of Materials Bill of Materials MUST be complete TOTAL $COST$ IS DUE TO WHS

STOP Jointing & Planing Joint one FACE and one EDGE Surface Plane to 5/8” THICK STOP Layout your Pieces on your Wood Like a JIGSAW Puzzle (Best Use of Wood)

YOU WILL BE LOSING POINTS FOR MISTAKES!! Ripping on Table Saw Review your Layout with Mr. Thuman Follow Instruction given (INDIVIDUAL): RIP on Table Saw Crosscut on SLIDING COMPOUND MITER SAW 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

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

Day 3 -- Ripping and Crosscutting Finished DImensions 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

Day 4 & 5 -- Laying Out ALL Joints & Labeling ALL Pieces 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

Day 6, 7 & 8 -- Cutting Finger Joints 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 Correctly Spaces Finger Joints 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”

Blade Cover Fence Indexing Pin/Stop Runners

Stop – prevents cutting through entire Jig

Use of Jig Second Cut – previous cut fits over INDEX PIN First Cut – Stock Against INDEX PIN Second Cut – previous cut fits over INDEX PIN

Completed Joint

Questions Ask Now!

Day 9 & 10 -- Cutting Sliding Dovetail 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 Use HOLLOW CHISEL MORTISER to make a SQUARE MORTISE across the BACK face of the DRAWER FRONT CENTERLINE of MORTISE is ¾” from EDGE ¾”

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!

Day 11 & 12 -- Cutting Rabbets, Dados & Grooves Wood 2 Box Project Day 11 & 12 -- Cutting Rabbets, Dados & Grooves

Objective & Tools Drawer 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!

Day 13 -- Assembling Drawer 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 Sand ALL INTERIOR surfaces of drawer parts Sand ALL surfaces that would be difficult to sand when assembled BE CAREFUL not to round over and edges or ruin any of your Joinery NEVER Sand any Joints or Surfaces that will be hidden by a joint

Gluing & Clamping Glue and Shim if needed the SIDES to the FACE Make sure they are SQUARE to FACE Glue and Clamp BACK into DADOs Make sure ENTIRE drawer is SQUARE Measure Diagonals – need to be equal Clean up Glue with Water Measure and Fit BOTTOM Panel

Center-Line of Clamp ALIGNED with Center-Line of Drawer Side Make sure Shoulders are TIGHT and Sides are SQUARE

Center-Line of Clamp ALIGNED with Center-Line of Drawer Side Make sure Shoulders are TIGHT and Drawer is SQUARE

Questions Ask Now!

Day 14 -- Cutting Drawer Opening 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!

Day 15 & 16 -- Box Dry Assembly & Sanding 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 Gaps or Cracks at Joints 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

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 Bucket of Water Softwood Bucket of Water

Glue Runners to Drawer Sides Runners SHOULD be slightly PROUD Plane to Fit Drawer Opening

Questions Ask Now!

Day 20 -- Fitting Dividers and Bottom 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

Day 21 -- Fitting Hardware Wood 2 Box Project Day 21 -- Fitting Hardware

Day 22, 23 & 24 -- Final Sanding and Finishing Wood 2 Box Project Day 22, 23 & 24 -- Final Sanding and Finishing

Last Day to Work IN Class 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

ALL QUESTIONS FROM WARM-UPS What’s On the Test? Stock Prep Four-Square Joinery Finger Joints, Dado, Rabbet, Groove, Dovetail Tool Use Jointer, Planer, Table Saw, Radial Arm Saw, Sliding Compound Miter Saw Measurement Adding and Dividing Fractions Reading a Ruler Reading a Machine Scale ALL QUESTIONS FROM WARM-UPS TEST IS OPEN NOTE