Alternative Methods Challenge-Project #4-Jewellery Box - Woodworking Talk - Woodworkers Forum
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post #1 of 51 Old 10-15-2011, 08:12 PM Thread Starter
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Alternative Methods Challenge-Project #4-Jewellery Box

In the original concept for the alternative methods challenge, there were 4 projects. Through the hustle, bustle and shuffle, one of those project got lost. Thanks to Longknife, it was resurrected and he did a fantastic job making it. I made a commitment to complete all of the projects in the challenge and when I make a commitment, I stick to it. With that being said, let's start making a jewellery box..................


The day started off like any other Saturday. A coffee, a bite to eat, a browse through the forum, and a trip to the shop. I picked through the walnut stack, to find usable pieces of walnut. I also picked out a nice 8/4 piece that I could mill for the cabinet of this project.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9721.jpg



I set the fence on my jointer, and made sure that it was 90 degrees to the table.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9722.jpg


I then surface planed the stock, checked it for flatness with a straight edge, and then edge jointed the piece to give me 2 perpendicular surfaces that were 90 degrees to each other. Hey, like my haircut?
Alternative Methods Challenge-Project #4-Jewellery Box-img_9723.jpg


After checking the stock for square, I moved on to my next step.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9724.jpg



I then set up my large bandsaw, to resaw the walnut into thinner pieces. I wanted to resaw the stock, leaving enough to thickness plane it after the resaw process.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9725.jpg

There is a very fine line between a "hobby" and a "mental illness"

Last edited by Kenbo; 10-15-2011 at 08:30 PM.
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post #2 of 51 Old 10-15-2011, 08:19 PM Thread Starter
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I then started the noisy process of thickness planing the stock to the size that I needed.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9727.jpg


1/2" is the required thickness and my calipers show me that I'm bang on.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9728.jpg


I jointed one edge of each 1/2" thick piece of stock to give me a good reference point to rip the stock.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9729.jpg


I set up my ripping blade in the table saw and squared it to the table. I then started to rip all of the 1/2" walnut to its required widths.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9730.jpg



Here, we can see all of the pieces in their needed widths.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9731.jpg

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post #3 of 51 Old 10-15-2011, 08:41 PM Thread Starter
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I installed my fine crosscut blade, checked it for square to the table, set up my miter gauge, and cross cut all of the pieces to their needed lengths.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9732.jpg



I then installed my dado blade in a 1/2" configuration and set its height to 1/4". I then cut all of the required dados and rabbets needed for the sides of the cabinet.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9733.jpg


I set my dado blade to a 1/4" configuration and set its height to 1/4". Using my setup blocks, I set the fence 1/8" from the blade and cut the dados needed to accept the backer board of the cabinet.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9735.jpg



A quick dry fit shows that everything is okay so far.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9736.jpg


Using my setup blocks, I set the fence 1/4" away from the blade.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9737.jpg

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post #4 of 51 Old 10-15-2011, 08:45 PM Thread Starter
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I then proceeded to cut the dados in the door pieces to accept the front panel.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9738.jpg


I cut the pieces needed for the two shelves of the jewellery box and performed a quick dry fit.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9739.jpg



I also cut the 1/4" ply needed for the backer board and checked for another dry fit. Using a square, I made sure that the cabinet of the jewellery box was fitting squarely.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9740.jpg



I glued and clamped the cabinet of the jewellery box together and cleaned up the shop for the night. Tomorrow, I will continue and see how far I get. Thanks for looking in.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9741.jpg

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post #5 of 51 Old 10-15-2011, 10:11 PM
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Thats alot of progress for one day! Keep up the good work!
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post #6 of 51 Old 10-15-2011, 11:20 PM
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great job superkenbo....man you make me tired just watching your pace

btw...how many hours so far?

lawrence

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post #7 of 51 Old 10-15-2011, 11:33 PM Thread Starter
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btw...how many hours so far?


Approximately 5 hours, give or take 30 minutes.

Thanks for the kind words guys. I'm looking forward to tomorrows work on this project.

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post #8 of 51 Old 10-15-2011, 11:45 PM
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Ken,I noticed a few things,You always do such fine work,this is another example.You have a lot of nifty tools,especially The things that make for accurate work.Your tools and shop look so clean.I did noticed your new haircut and I hate to get personal but is that the start of a Hot Dog starting to grow on the back of your neck??:lau ghing:

***For the record*** Ive made hundreds of guitar bodies,never put one together and cant play a note.
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post #9 of 51 Old 10-15-2011, 11:57 PM Thread Starter
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Originally Posted by Itchy Brother View Post
is that the start of a Hot Dog starting to grow on the back of your neck??:lau ghing:

More like an Octoberfest sausage Gary.

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post #10 of 51 Old 10-16-2011, 12:16 AM
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Ken, you continue to amaze me at every turn. I wish I had half the kewl stuff in my shop as you have in yours. Heck, I wish I was half as good at this as you are. Seems like every cut is pure perfection. Except for the one on your head.... I like my hair cuts to be farther away from my head.....

If Woodworking is so much fun why isn't it called WoodFUNNING?

I've made a few videos
http://www.youtube.com/user/johnnie52

Last edited by johnnie52; 10-16-2011 at 12:38 AM.
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post #11 of 51 Old 10-16-2011, 12:18 AM
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Man, that's a lot for one day! This is one I'm planning to tackle so I'm happy to see you walk through it first. (I will take considerably more time to finish!)
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post #12 of 51 Old 10-16-2011, 01:20 AM
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Quote:
Originally Posted by Itchy Brother View Post
Ken,I noticed a few things,You always do such fine work,this is another example.You have a lot of nifty tools,especially The things that make for accurate work.Your tools and shop look so clean.....
Itchy, I forgot who first called him the Hall of Famer, but they were spot on. Does the woodworking forum have a Hall of Fame or was Kenbo inducted into another kind? He knocks 'em outa the park every time! bill

The answer to your question will only be as detailed and specific as the question is detailed and specific. Good questions also include a sketch or a photo that illustrates your issue. (:< D)
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post #13 of 51 Old 10-16-2011, 01:35 AM
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as usual ken an amazing project!
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post #14 of 51 Old 10-16-2011, 05:49 AM
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Looking good bud!

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post #15 of 51 Old 10-16-2011, 09:10 AM
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Ken, I just started gathering my wood last night for the machinest chest and you're already finished with the carcass on this! As usual, excellent work, and a fine start to the write up. I'm looking forward to your finished project, as I already really like the walnut.
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post #16 of 51 Old 10-16-2011, 06:43 PM Thread Starter
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Thanks for all of the compliments and words of encouragement guys. They are greatly appreciated.
Today started off like yesterday. A coffee, a bite to eat, a quick browse through the forum and a journey to the shop. Not much of a journey seeing that my shop is in my back yard but a journey none the less.
As much as I love the look of walnut, I love the look of contrast even more. It is for that reason, that I have chosen to use contrasting woods for this jewellery box. I pulled down a piece of maple and cut it to length. I then set up my jointer and checked the fence for squareness to the table. I then surface jointed the stock, checked it for flatness and then edge jointed, checking once I was done for perpendicular surfaces that were 90 degrees to each other.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9743.jpg


I set up my bandsaw for some resaw action. I used my setup blocks to set the resaw fence at a little more than twice the required thickness of the final stock. In this case, it is set to 1 1/8". I also checked to make sure that the blade was square to the table. You can see here that I used my digital meter for this. I use this gauge for everything and I love it.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9744.jpg


Once I got the maple cut, I set up the thickness planer and planed the cut surface parellel to the jointed surface. I only took off enough stock to remove the blade cut lines from the bandsaw.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9745.jpg


After thickness planing, I reset the fence of my bandsaw to cut the stock in half. I was hoping to acheive some nice bookmatching, but the grain in this maple is really not that spectacular. I'm sure that it will be a little better when the finish is put on to bring out the grain a little more.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9746.jpg


I jointed one edge of each piece of maple, and set up my ripping blade in the table saw. I made sure that it was 90 degrees to the table and cut my stock to 1/2 of the final width of the board. In this case, it was 4 1/8".
Alternative Methods Challenge-Project #4-Jewellery Box-img_9747.jpg

There is a very fine line between a "hobby" and a "mental illness"
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post #17 of 51 Old 10-16-2011, 06:58 PM Thread Starter
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I applied glue to both inside surfaces and set up my bar clamps.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9748.jpg


We can see here that I have quite a bit of squeeze out happening. I'm not too concerned. I also opted not to use cauls, but instead, clamped the boards down to the bar clamps.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9749.jpg


After the glue has set for 10-15 minutes, I use a scraper and the squeeze out comes off quite easily. You can see how clean the area is behind the scraper.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9750.jpg


I put my maple panel aside to dry and I moved on to the drawers. I dug through my scrap maple pile because I'm hoping to use some of the scrap that I have for this project. I found quite a bit of scrap that was useable.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9751.jpg


I jointed, thickness planed and ripped to width all of the scrap maple that I would need. I then set up my fine cross cut blade and my miter gauge and cut all of the drawer pieces to the correct lengths. While I had the miter gauge and blade set up, I also unclamped my maple panel and cut it to the required length.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9752.jpg

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post #18 of 51 Old 10-16-2011, 07:07 PM Thread Starter
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I installed my dado blade in the table saw in a 3/8" configuration, and using my setup blocks, I set the height to 1/4". Using my miter fence, I cut the rabbet on each end of the maple panel. I then set up my table saw fence and cut the rabbet in each side of the front surface of the panel.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9753.jpg


A dry test fit looks good.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9754.jpg


I then sanded the interior of the walnut pieces and both sides of the maple panel to a grit of 220.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9755.jpg


After the clamping of the door assembly, I check to ensure that everything is square and leave the door to dry. Be sure to clean up any squeeze out before it dries.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9756.jpg


Considering that my dado blade is already set up as is my miter fence, I then cut the rabbets needed for the front and back pieces of each of the drawers.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9757.jpg

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post #19 of 51 Old 10-16-2011, 07:14 PM Thread Starter
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I installed my ripping blade and made sure that it was 90 degrees to the table. I set the height of the blade and set my fence to make the 1/8" dado to accept the drawer bottom and leave 1/8" of material at the bottom of the drawer.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9758.jpg


You can see here that all of the dados have been cut in the bottom of all of the side pieces.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9759.jpg


Using the same setup, I also cut the dados in the lower end of the front and back pieces of the drawers.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9760.jpg


I then cut the 1/8" hardboard panels for the drawer bottoms.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9761.jpg


A dry fit showed everything was A-okay, so I glued up the drawers, clamped them and checked them for square. Everything's looking good here.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9762.jpg

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post #20 of 51 Old 10-16-2011, 07:19 PM Thread Starter
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Once the glue was dried, I sanded the door, the case and the drawers to a grit of 220. This next photo is just a gentle reminder to keep safety in mind. Safety is not necessarily about keeping your fingers, it's also about keeping the dust out of your lungs. Keep respitory safety in mind too guys, it's important.
Alternative Methods Challenge-Project #4-Jewellery Box-img_9763.jpg


And this is where I am at now. Tomorrow I am going to have to come up with something because the recipient of this jewellery box doesn't want a ring holder in it so I have to come up with something else for that space. Either way, this project is coming along nicely and tomorrow I will continue and see where we end up. Thanks for looking in guys.
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