Alternative Methods Challenge - truly slantsided box - Woodworking Talk - Woodworkers Forum
 
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post #1 of 16 Old 10-18-2011, 03:29 PM Thread Starter
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Alternative Methods Challenge - truly slantsided box

I was thinking about the slantsided jewelry box and how to apply any alternative methods on that. Then I thought that it could be fun to try to make it with truly slanted sides of consistent thickness instead of beveling the sides on the table saw.

This implicate a complex joinery - a compound joint with both a miter and a bevel. To calculate the angles I used the Compound Saw Calculator. The angle of the sides are 8 deg and when I calculated that I got the Miter Angle 7.9 deg and the Blade Tilt 44.4 deg.

Easy enough, but how do I set that up on my table saw? I don't have a tilt box and a digital protractor but as far as I understand these gadgets have an accuracy of 0.1 deg so maybe they are not the full answer either.

I decided to go for the trial and error method. I set my TS crosscut fence to approx 8 deg (in my case closer to 10 than 5).
No rocket science so far.......

Alternative Methods Challenge - truly slantsided box-dsc00406.jpg

Then I tilted the blade to between 44 and 45 deg, picked up some scrap stock and started to make test cuts. I didn't move the fence, all adjustments were made with tilting the blade. After just a couple of trials I had a good fit, a square corner and a side angle of approx 8 deg.

Alternative Methods Challenge - truly slantsided box-dsc00407.jpg
Alternative Methods Challenge - truly slantsided box-dsc00408.jpg

I resawed some birch for the side blanks, jointed, planed and cut them to size. Then I cut the miter on the left corner. To cut the other I had to reset the fence to 82.1 deg. This required some new test cuts on scrap pieces (this time I tweaked the fence, not the tilt) and then cut the other corner.

Next I had to do was to cut a bevel on the edges of the sides boards so that both bottom and top edges are horisontal. I used a bevel gauge to find the angle....

Alternative Methods Challenge - truly slantsided box-dsc00409.jpg

..... and used it to set the blade at that angle.

Alternative Methods Challenge - truly slantsided box-dsc00410.jpg
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post #2 of 16 Old 10-18-2011, 03:41 PM Thread Starter
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Then I ripped both edges on all pieces.

Alternative Methods Challenge - truly slantsided box-dsc00411.jpg

On the top edge there will be a rabbet for the lid and on the bottom edge a rabbet for the bottom. These rabbets must be cut with an angle to be horisontal. To accomplish that I made a simple jig.

Alternative Methods Challenge - truly slantsided box-dsc00412.jpg

I then used the jig in the shaper to cut the rabbet on the upper edges.

Alternative Methods Challenge - truly slantsided box-dsc00416.jpg

When cutting the rabbet for the bottom I flipped the board and raised the shaper knifes to cut from above.

Alternative Methods Challenge - truly slantsided box-dsc00418.jpg

I also made the rabbet for the back in the sides and cut the back to size. A dry fit showed tight joints and square corners.

Alternative Methods Challenge - truly slantsided box-dsc00419.jpg

That will be it for now, will be back soon for the rest. Thanks for watching.
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post #3 of 16 Old 10-18-2011, 07:51 PM
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Okay, now you're just showing off. That is absolutely awesome. I love the fact that you took this one stage further than I did. Great work. I'll be watching this one most definitely.

There is a very fine line between a "hobby" and a "mental illness"
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post #4 of 16 Old 10-18-2011, 08:31 PM
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OH Yeah! Gotta watch this one for sure. I love it when a person can adapt to his tools and still produce a great piece!

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

I've made a few videos
http://www.youtube.com/user/johnnie52
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post #5 of 16 Old 10-18-2011, 11:03 PM
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Now that's what I'm talking about! I was just thinking about this earlier and you went and did it. Definitely going to keep an eye on this one.
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post #6 of 16 Old 10-19-2011, 01:41 PM
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Very Nice

WOW. I like how you adapted your tools to get the results you needed.
That is "Thinking Outside of The Box"

Pun was most definately intended.

Tools are like guns, You can never have enough.
Where did I put that tape measure???
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post #7 of 16 Old 10-19-2011, 03:45 PM Thread Starter
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Had a few things made today. I made a template for the handle recess, clamped it on the front board and routed the recess.

Alternative Methods Challenge - truly slantsided box-dsc00421.jpg

Then I assembled the sides, glued and clamped them. I also cut the bottom from 4 mm plywood and when the box glue-up was cured I glued the bottom in the rabbet.Next thing to do was the slots for the miter splines and for that I hade to make a jig.

Alternative Methods Challenge - truly slantsided box-dsc00423.jpg

It took some thinking and measuring to get the right sizes of the slots due to the slanted sides.
Alternative Methods Challenge - truly slantsided box-dsc00424.jpg

My ATB blade doesn't leave a flat bottom in the saw kerf so I adjusted that with a thin file.
Alternative Methods Challenge - truly slantsided box-dsc00422.jpg

Then I planed the stripe blanks for the splines. My sawblade leaves a 3.2 mm kerf so I needed the stripes to be of that thickness. However my planer can only cut down to 4 mm. Therefore I attached the stripes to a support board with double-sided tape.I cut the pieces for the splines, glued and installed them.

Alternative Methods Challenge - truly slantsided box-dsc00425.jpg

Tomorrow hopefully I will make the lid and the feet.
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post #8 of 16 Old 10-19-2011, 05:45 PM
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Very nice work getting the compound cuts to work. Looking great so far.
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post #9 of 16 Old 10-19-2011, 10:26 PM
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The quality of your work is definitely an inspiration. I'm really enjoying this thread.

There is a very fine line between a "hobby" and a "mental illness"
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post #10 of 16 Old 10-20-2011, 12:39 AM
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Did you make a "special" holder for the box to cut the slots with the sides already angled or just raise the blade to reach the work?

I was wondering how you would manage to get the slots after you had the angles on the box. I see you got it done. Very nice.

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

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post #11 of 16 Old 10-20-2011, 10:28 AM Thread Starter
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Quote:
Originally Posted by johnnie52 View Post
Did you make a "special" holder for the box to cut the slots with the sides already angled or just raise the blade to reach the work?

I was wondering how you would manage to get the slots after you had the angles on the box. I see you got it done. Very nice.
I just raised the blade, but it took some thinking and measuring to get it right. There are two different heights too, one for the upper and one for the lower slot.

What I did was to first measure the distance from the saw table to the box wich I did with this setup

Alternative Methods Challenge - truly slantsided box-dsc00429.jpg

Then I measured how deep the cut could be without cutting through the corner

Alternative Methods Challenge - truly slantsided box-dsc00430.jpg

Those two distances added gives the blade hight wich I set with my set up gauge

Alternative Methods Challenge - truly slantsided box-dsc00431.jpg

Then I set the fence at the correct distance an made the slot.
For the other slot I had to lower the blade and reposition the fence

Alternative Methods Challenge - truly slantsided box-dsc00432.jpg
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post #12 of 16 Old 10-20-2011, 01:28 PM Thread Starter
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What I did today was to cut off the excess from the splines with a fine-toothed saw. The remaining I cut away with a sharp chisel...

Alternative Methods Challenge - truly slantsided box-dsc00428.jpg

... and finally I sanded them down flush with the sides.

Alternative Methods Challenge - truly slantsided box-dsc00437.jpg

Next to do was the mortises for the hinges. I cut them out with a chisel.

Alternative Methods Challenge - truly slantsided box-dsc00433.jpg

Then I cut the lid and the feet to size. I didn't glue an extra piece to the lid as the handle, instead I cut the handle out of the lid itself.

Alternative Methods Challenge - truly slantsided box-dsc00434.jpg
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post #13 of 16 Old 10-20-2011, 01:35 PM Thread Starter
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I wanted to have the lid to stay in an upright position when opened. (I maybe will add a mirror to the inside of the lid). Therefore I left a lip on the back edge of the lid.

Alternative Methods Challenge - truly slantsided box-dsc00435.jpg

This lip will rest on the back of the box and hold the lid upright.

Alternative Methods Challenge - truly slantsided box-dsc00436.jpg

I have applied a first coat of BLO. I will wetsand it to P600 grit and give it two more coats.

Alternative Methods Challenge - truly slantsided box-dsc00439.jpg

There will also be a felt lining in the bottom (haven't glued it in yet thogh)

Alternative Methods Challenge - truly slantsided box-dsc00440.jpg
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post #14 of 16 Old 10-20-2011, 03:43 PM
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Excellent looking jewelry/music box, Longknife. I'm sure the recipient will Love it.
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post #15 of 16 Old 10-21-2011, 12:00 AM
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I've said it before, and I'll say it again. Beautiful work.

There is a very fine line between a "hobby" and a "mental illness"
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post #16 of 16 Old 10-21-2011, 01:23 AM
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So very, very nice. Whoever is going to be getting this one will love it.

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

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