I'm planning on making an '11 groove box' like in a relatively recent Roy Underhill episode (link here) for my son to give as a gift.
But... I'm not going the all hand tools route, at least partly because I don't have any kind of plow plane. The basic design is 4 mitered sides with splines, top and bottom inserted in grooves all around, then cut open to form lid, with a tongue inserted in a groove to make a lip... I think that anyone who has made one knows what I'm talking about. Stock will be 2/4 x 6" red oak s4s from HD.
I'm trying to plan the operations with the tools that I have and want to get some advice on whether those who have experience in such things think they are a good approach:
1. Use router table to cut all grooves, including 1/8 around sides for bottom and 1/2" wide groove for the spline that will make the lip and lid.
2. Perhaps I could cut the tongue on the bandsaw and plane down to finished width.
3. Spline making - I could use router to make a little jig to hold the pieces to plane down to size a la Roy. I also have a bandsaw. For the splines I suppose I could try to resaw to the correct thickness and shave off anything required to get the splines to fit. This part of the project seems like a PITA.
4. Cut mitres on power mitre saw, with tongue in place. I have a new Dewalt 40 or 60 tooth (can't remember) blade I can put on. I was planning on holding the stock upright against the fence. I know the miters need to be precise but I'm concerned about splintering on the saw. Thoughts?
5. use router table and a piece of scrap cut at 45 degrees to support sides to cut the 1/8 dado for the spline. The dado is in the end grain; I would have the piece supported by the 45 degree scrap to maintain the correct angle, and the edge of the board would be pushed up against the fence. Does this sound feasible?
6. Cut the box open after gluing to make the lid on the bandsaw., then glue in the tongues.
Finally, any suggestions for adding words to the lid that a 4 year old could participate in making? One thought was tracing over letters with a hammer and nail to make indentations. Other thoughts would be appreciated.
Thanks in advance for any insight.
But... I'm not going the all hand tools route, at least partly because I don't have any kind of plow plane. The basic design is 4 mitered sides with splines, top and bottom inserted in grooves all around, then cut open to form lid, with a tongue inserted in a groove to make a lip... I think that anyone who has made one knows what I'm talking about. Stock will be 2/4 x 6" red oak s4s from HD.
I'm trying to plan the operations with the tools that I have and want to get some advice on whether those who have experience in such things think they are a good approach:
1. Use router table to cut all grooves, including 1/8 around sides for bottom and 1/2" wide groove for the spline that will make the lip and lid.
2. Perhaps I could cut the tongue on the bandsaw and plane down to finished width.
3. Spline making - I could use router to make a little jig to hold the pieces to plane down to size a la Roy. I also have a bandsaw. For the splines I suppose I could try to resaw to the correct thickness and shave off anything required to get the splines to fit. This part of the project seems like a PITA.
4. Cut mitres on power mitre saw, with tongue in place. I have a new Dewalt 40 or 60 tooth (can't remember) blade I can put on. I was planning on holding the stock upright against the fence. I know the miters need to be precise but I'm concerned about splintering on the saw. Thoughts?
5. use router table and a piece of scrap cut at 45 degrees to support sides to cut the 1/8 dado for the spline. The dado is in the end grain; I would have the piece supported by the 45 degree scrap to maintain the correct angle, and the edge of the board would be pushed up against the fence. Does this sound feasible?
6. Cut the box open after gluing to make the lid on the bandsaw., then glue in the tongues.
Finally, any suggestions for adding words to the lid that a 4 year old could participate in making? One thought was tracing over letters with a hammer and nail to make indentations. Other thoughts would be appreciated.
Thanks in advance for any insight.
