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 ONCONDITION OFLUMBER

Example

• Finished Dimension: 3 ¾” x 16” x ½”• Rough Dimension: 4 ¼” x 18” x 1”

W X L X H/1444.25” x 18” x 1”/144

76.5”/144BF=.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 $$$$0 bf

• Poplar $$$$$ bf

• Bubinga $15.90 bf

• Red Oak $$$$$ 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

STOP3. 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. Thuman2. Follow Instruction given (INDIVIDUAL):

1. RIP on Table Saw2. Crosscut on SLIDING COMPOUND MITER

SAW1. 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 SIDET

HIS

SID

E

TH

IS S

IDE

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!!??

Pa

rt N

am

e &

Qu

anti

ty

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”

Runners

Fence

Blade Cover

Indexing Pin/Stop

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

• 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!

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 SidesOnly

Drawer Side (x2)

• Completed AFTER Dovetail Pin• Need a MATCHING PAIR (Opposite)

Rabbet: ¼” wide x 1/8” deep

Dado: ¼” wide x 1/8” deep

¼”

Box Bottom (x4)

• After Finger Joints are milled

Groove: ¼” wide x 5/16” deep

Cannot go thru a Finger

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 DADOs1. 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 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!

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

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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 ProjectDay 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, 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