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Ebooksclub.org Basic Box Making

Ebooksclub.org Basic Box Making

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Published by Bianca Dubar

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Published by: Bianca Dubar on Aug 01, 2011
Copyright:Attribution Non-commercial

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10/17/2013

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the sliding toP of this box is based

on the concept of the tongue-and-groove joint.
A tongue formed on the sides of the lid allows it
to slide within the grooves cut into the box sides.
Because it requires no fitting of hardware and all
the cuts can be made at the tablesaw, this is one
of the easiest ways to add a lid to a box.
To cut the grooves in the sides, I use a 1⁄8-in.-
kerf combination blade that has square teeth
(instead of raked ones) because it allows you to
cut flat-bottomed grooves in the sides.

1. Raise the blade 1⁄8 in. above the table height,
then set the fence 3⁄8 in. from the outside edge of
the blade. This allows you to cut the lid from 3⁄8-in.
stock, then sand just a bit of the sides flush to the
lid during final shaping.

Cut the sides
for the lid to
fit Use the table-
saw with a 1

⁄8-in.-
kerf combination
blade to groove
the box sides to
accept the lid.
Use a push stick
to hold the stock
securely through-
out the cut.

2. Use a push block to guide the box sides
through the cut. On cuts like this—where the saw
teeth are buried beneath the face of the wood—the
stock has a tendency to lift off the blade and leave
shallow spots in the groove. Using a push block
helps keep the stock flat to the table throughout
the cut (photo a ).

It is easier to sand the interior of small
boxes before they have been assem-
bled. The outside surfaces can be
sanded once assembly is complete.

work

smart

a

48 A Sliding-Top Pencil Box

trim the height of the ends To allow the lid to side
freely across the ends of the box, cut away the top of the
box ends. Take your measurement for this step directly
from the height of the groove cut on the box sides.

3. After the slots are cut in the sides, raise the
blade and trim the height of the box ends to allow
clearance for the lid to slide open. To determine the
fence location, measure from the bottom of the box
sides to the edge of the groove cut for the sliding
lid, then subtract 1⁄32 in. for extra clearance. Because
this stock is so small, use a push stick to guide the
ends through the cut (photo B ).

Assemble the box

if you attained a good fit in cutting

the joints, the box should go together smoothly
without requiring any clamps. Very little glue is
required to lock the joints in place and secure
them for years to come.

1. Use a small squeeze bottle to apply glue to one
set of fingers. As the joint is pushed together, the glue
will spread and secure the joint. Attach the two short
ends to one of the long sides, then slide the bottom
into place and attach the last side (photo a ).

2. Make certain that the box is square before
the glue dries. Either measure corner to corner
and make adjustments until the two measures are
identical, or check to see that the bottom panel fits
evenly on all sides. In assembling this box, no glue
should be applied to the bottom panel, leaving it
free to expand and contract as humidity changes.

3. If the parts fit together tightly, there is no
need to add clamps. If the fit is a little loose, use
rubber bands, tape, or clamps to hold the corners
in position until the glue sets.

assemBle the Box Apply glue to the fingers using a
squeeze bottle. Start with one side, add two ends and the
bottom, then the other long side. No glue is required to
secure the bottom. If the joints are well-fitted, no clamps
are needed.

a

B

A Sliding-Top Pencil Box 49

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