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Wood 2 Box Project Intro
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Skill Objectives Stock Preparation Joinery Jointer Surface Planer
Table Saw Joinery Finger Joint Rabbet Dada Sliding Dovetail
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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
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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
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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”
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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
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Example Finished Dimension: 3 ¾” x 16” x ½”
Rough Dimension: 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 X $3.10 = $1.65
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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
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How Much $$$$$$$ Wood Available: Soft Maple $3.10 bf
Cherry $4.90 bf Poplar $2.85 bf Bubinga $15.90 bf Red Oak $3.20 bf
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Day 2 -- Stock Selection and Prep
Wood 2 Box Project Day 2 -- Stock Selection and Prep
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Safety Tests You must have passed the following tests with a 100%
Jointer Surface Planer RAS Sliding Compound Miter Saw
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6” X 36” 6” X 20” Selecting Your Stock Wood is EXPENSIVE
ASK, DOUBLE CHECK, TRIPLE CHECK BEFORE YOU DO ANYTHING! 6” X 36” 6” X 20”
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Available Wood Soft Maple $3.10 bf Cherry $4.90 bf
Poplar $2.85 bf Bubinga $15.90 bf Red Oak $3.20 bf
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TOTAL $COST$ IS DUE TO WHS
Bill of Materials Bill of Materials MUST be complete TOTAL $COST$ IS DUE TO WHS
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STOP Jointing & Planing Joint one FACE and one EDGE
Surface Plane to 5/8” THICK STOP Layout your Pieces on your Wood Like a JIGSAW Puzzle (Best Use of Wood)
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YOU WILL BE LOSING POINTS FOR MISTAKES!!
Ripping on Table Saw Review your Layout with Mr. Thuman Follow Instruction given (INDIVIDUAL): RIP on Table Saw Crosscut on SLIDING COMPOUND MITER SAW Remember to SQUARE UP ONE END!!! YOU WILL BE LOSING POINTS FOR MISTAKES!!
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Cutting Accuracy & Time
ACCURACY IS IMPORTANT IF YOU WANT YOUR BOX TO LOOK GOOD!!! TAKE YOUR TIME AND DO IT CORRECTLY THE 1ST TIME!
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Basic Geometry IF YOU WANT A SQUARE BOX THIS SIDE THIS SIDE THIS SIDE
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How Much $$$$$$$ Wood Available: Soft Maple $3.10 bf
Cherry $4.90 bf Poplar $2.85 bf Bubinga $15.90 bf Red Oak $3.20 bf
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Day 3 -- Ripping and Crosscutting Finished DImensions
Wood 2 Box Project Day 3 -- Ripping and Crosscutting Finished DImensions
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Safety Tests Andrew Aberts Tera Baker Doug Blank Paul Hassett
Chad Lawson Billy Rittelmeyer Mike Shafer
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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
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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
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Procedure Form EVERYONE MUST complete the Procedure Form
Each Step needs to be SIGNED OFF by Mr. Thuman
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Questions!!??
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Part Name & Quantity
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Day 4 & 5 -- Laying Out ALL Joints & Labeling ALL Pieces
Wood 2 Box Project Day 4 & 5 -- Laying Out ALL Joints & Labeling ALL Pieces
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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
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Missing Pieces? Make sure you have ALL your pieces
See Mr. Thuman if you don’t Share between Students
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Safety Tests Band Saw Belt/Disc Sander Portable Tools
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Safety Tests Unless you have passed ALL safety tests with a 100% you will not use any tools
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Day 6, 7 & 8 -- Cutting Finger Joints
Wood 2 Box Project Day 6, 7 & 8 -- Cutting Finger Joints
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Objective Understand BASIC concepts of Finger Joint Layout
Understand use of Finger Joint JIG Cut Finger Joints using Table Saw
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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
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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
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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
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Good and Bad ALL EQUAL
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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”
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Blade Cover Fence Indexing Pin/Stop Runners
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Stop – prevents cutting through entire Jig
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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
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Completed Joint
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Questions Ask Now!
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Day 9 & 10 -- Cutting Sliding Dovetail
Wood 2 Box Project Day 9 & 10 -- Cutting Sliding Dovetail
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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
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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”
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2nd Step Cut PIN on both DRAWER SIDES Use Layout JIG for SHOULDER MARK
Use Layout JIG for CHEEK Depth
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3rd Step Use BANDSAW to cut PIN
Cut from Outside Corner to CHEEK DEPTH mark
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4th Step Using PIN as guide, trace the angles onto DRAWER FACE
Use a CHISEL and SLOWLY angle the cheeks of the square mortise
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5th Step Patience Take you TIME and go SLOWLY You want it to be a SNUG fit
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Questions Ask Now!
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Day 11 & 12 -- Cutting Rabbets, Dados & Grooves
Wood 2 Box Project Day 11 & 12 -- Cutting Rabbets, Dados & Grooves
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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
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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
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Box Bottom (x4) After Finger Joints are milled Cannot go thru a Finger
Groove: ¼” wide x 5/16” deep
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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
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Questions Ask Now!
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Day 13 -- Assembling Drawer
Wood 2 Box Project Day 13 -- Assembling Drawer
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Materials Needed Sander (Dual Action) Sand Paper
80grit, 100grit, 120grit, 150grit Bucket of Water AND Rag Glue Clamps Index Cards for Shims
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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
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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
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Center-Line of Clamp ALIGNED with Center-Line of Drawer Side
Make sure Shoulders are TIGHT and Sides are SQUARE
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Center-Line of Clamp ALIGNED with Center-Line of Drawer Side
Make sure Shoulders are TIGHT and Drawer is SQUARE
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Questions Ask Now!
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Day 14 -- Cutting Drawer Opening
Wood 2 Box Project Day 14 -- Cutting Drawer Opening
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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
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Questions Ask Now!
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Day 15 & 16 -- Box Dry Assembly & Sanding
Wood 2 Box Project Day 15 & 16 -- Box Dry Assembly & Sanding
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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
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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
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Sand to 150grit Sand ALL interior Surfaces 80grit 100grit 120grit
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Questions Ask Now!
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Wood 2 Box Project Day 17 -- Box Assembly
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Materials Glue Bucket of Water and Rag AT LEAST 4 Clamps
Maybe More Make sure you CLEAN UP ALL glue
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Questions Ask Now!
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Wood 2 Box Project Day 18 & 19 -- Fitting Drawer
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Objective Fit the drawer to the ASSEMBLED BOX so that is slides smoothly
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Material Glue Tape Pre-Made Runner – 9/16” x 9/16 Bucket of Water
Softwood Bucket of Water
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Glue Runners to Drawer Sides
Runners SHOULD be slightly PROUD Plane to Fit Drawer Opening
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Questions Ask Now!
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Day 20 -- Fitting Dividers and Bottom
Wood 2 Box Project Day 20 -- Fitting Dividers and Bottom
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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
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Procedure
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Day 21 -- Fitting Hardware
Wood 2 Box Project Day 21 -- Fitting Hardware
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Day 22, 23 & 24 -- Final Sanding and Finishing
Wood 2 Box Project Day 22, 23 & 24 -- Final Sanding and Finishing
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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
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Unit Test Tuesday May 1st
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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
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