Just using up some scraps

[bandit571]

Wasn't sure IF anyone wanted to follow along....involves a bit of saw work..
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To transform 4/4 scraps into 3/8" stock....
More saw work..

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To make hand chopped box/finger joints....
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Not to mention a lot of hand plane work..

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Both the flatten the sawn faces of the boards, but...
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Jointing a few edges, in case I want a glued up panel for a lid..
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Have 3 out of 4 corners milled, trying to get the grain to wrap around the box....

So...IF anyone wants, I could start a build along thread.....Has the usual suspects...
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Although, one is under arrest...
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Knife to do "Knife Wall" work.....assaulted a thumb on the way by..
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Never felt a thing.   So, anyone interested?

[bandit571]

Ok, to get started...had a stack of scraps from the Table project..
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So. to reduce the thickness and double the board count,   set the saw blade as high as it could go.  Set the rip fence to the center of the board's width..
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Hmm, doesn't reach quite far enough, does it?  We have ways..
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Happen to have a D8 Rip saw handy ( just been sharpened, BTW) so...the shorter 3 boards used this set up..
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Have to be careful, as when I reach the bottom of the cut...
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The halves tend to pop apart....soon had 6 blanks..
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From 3 planks.   The longer 3 planks, I wanted a bit more elbow room...to get that 28" stroke..
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Used a c clamp to keep things from tipping over.   Got down to about 1-2" from that clamp, flipped the board over, and came down from the other end..
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Soon had 6 of the longer wider boards....all were just a hair over 3/8" thick....some will need a bit more work than others..
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Still had a stack of narrows....
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I figure I can rip these as needed....as for the resawn stuff...will need a plane..

That will be next time......stay tuned

[hbmcc]

Man!! How do you manage hand sawing? 

I had ambitions to do the same hand work but my new shoulder is giving me fits. A whole bunch weaker and a real chore to get over the pain hump when planing and sawing. I'm redoing the front porch this summer.

I guess you just barrel through it....

Look forward to watching your progress, Steve.

[bandit571]

That D8 had just been sharpened up...needed to be used.   Nice long full strokes, about like a pit sawyer would use....no need to get into any rush....just let the saw do the work.    Each stroke cuts quite a bit down through.   By using the tablesaw to cut those kerfs, I even saved a bit of work....much easier to start the saw.

Tablesaw also was used to 4-square the longer blanks,,going from...
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A mess like this to..
 
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All squared away.   Then the planes can take over...a "Before & After" look...
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So that when both halves are planed smooth and flat...
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All that is needed is some jointer work..
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So I can have a decent book match..
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This one is a bit too "busy"....will use something more like this for a lid...
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Some needed a little bit of beltsanding...most took a Millers Falls No. 15....a couple spots I used the Millers Falls No. 9, Jointing was with the WR No. 62...
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This being the No. 15 in use.....slightly larger than a normal No. 5 Jack plane...
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Like this Millers Falls No. 14.  Plan right now, is to take the largest 2 from this stack, and the narrow two from the 12" long stack, match them up into 4 sides of a box..
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May involve a few rip cuts, and a few crosscuts until they all match in width, width squared ends..
Stay tuned..

[bandit571]

4 sides...2 at 8" long,  2 at 12" long.....3/8" thick (more or less) by 3-5/8" tall...
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Will do as a start...need to round up all the usual suspects...for making finger/box joints by hand tool..
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Hmmm...missing one...must be upstairs...
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To make a knife wall, one needs a knife.   The chisel was first, needed to set the spacings of the fingers..
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usually right on the end grain...sometimes two boards go through the layout...
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Then that small square can carry the marking around...
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With the marking gauge providing a "stop line" to mark the saw lines to.   usually works best IF just one part is sawn at a time..
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Saw does not like a lot of vibration either....I keep the board low in the vise....works, since I am usually sitting down on the shop stool to do this sort of work...about 8 full strokes to complete each cut....then set up a chopping board ( to protect the top of my bench, right) and cut the knife wall..
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Grab that chisel again....I chop down about 1/2 way....leave a little porch out on the ends...then flip the board over..
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And complete the chopping...all nice and clean...I start from the outside (show) side first, then finish the chops from the "inside"....need to mark which is which, too
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Tends to be very useful information....panels all tend to look alike.    I work from the shorter "ends" first.   Once those fingers are chopped, I use them to lay out the matching fingers on the "side" panels....and saw and chop those. 

Stay tuned..

[bandit571]

Ok, sides were getting sawn and chopped to match...Had one end that needed a bit extra work....seems that fancy grain...

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Caused that middle finger to break off....so, the side had to match that..
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Got into a issue...as to which corner was next...and still allow the grain to flow around the box...instead of #3...#4 was done...
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Dry fit?
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Even sits square.   Next shoptime, #3 corner was sawn..
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Chopped..
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And dry fitted....
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So...next time will be a glue up adventure....

stay tuned..

[bandit571]

Glue up time!
  First a dry run with the clamps...to preset them so I don't have to stand there and fumble with them AND wet glue..
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8....just 8?...for now...Bought a bag at Harbor Freight the other day...
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And got out a couple...
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Lots of fingers to spread the glue around...one brush to spread with, the other to clean off any squeeze outs...OK, let the fun begin..

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Put a couple LONG (18") clamps on first, stick the ends down into the vise....then let the flash mob continue...pine stays to prevent bowing in on the ends
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Turned out, I also needed a couple to prevent the sides from also bowing in...c clamps needed to pull the stays into place,,,with a few well aimed hammer shots..
 

Added 2 more in the middle of the ends, had an issue with that spot not closing up

Clamp Count? 12....will wait and see...how well it turned out...Sunday night.  


Stay tuned

[bandit571]

Clamps can come back off, now.....slowly..

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First 8 removed, leaves...

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Four 18" long clamps....then a bit of clean up...
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Between a beltsander to wear down the high fingertips, and a smooth plane to level the rest of each side.   I left a couple spacers in, due to a side that kept trying to bow in..
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Set this aside, for now....worked on the lid a bit..jointed the edges for the glue joint...
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See how it goes together....
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Might as well glue it up?
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and let this sit a day....

Bottom panel is a 1/4" plywood panel, that will get glued down to "Slips".    First, I need to rip a bit of stock once..
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Took 2 passes, otherwise the board slips down into the saw...or worst.   and ruins my store bought pushstick.....reset the fence a bit..
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This is the shop-built pushstick....been nicked a few times.   Long enough to guide the entire piece through.    I can then go back, and plane these 4 blanks smooth.
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Slips will then get glued in place, with a mitered corner....need a Mitersaw for that.  waiting on glue to dry...again...


Stay tuned

[bandit571]

Slips have been cut to length..
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Cordless Mitersaw?  Each was then glued and clamped into it's place..
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With however many clamps it took...most of the joints were fairly tight...
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There always seems to be That One, though...
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Let this mess sit a day....
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Next day..cut a 1/4" thick plywood panel for the bottom of the box.    Brush a bead of glue along the slips...use a set of cauls to press the panel down into the glue...Then work on the blank for the lid...bandsaw to round 2 corners..
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Millers Falls No.9 to smooth both faces..
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Spokeshave is to remove the burn marks left by the bandsaw.    It was also to help round over the edges..
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To help?  Well, there is a Stanley No. 9-1/2 also at work, here.    It also shot the end grain straight...and ..
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Worked with the spokeshave...
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had to make a run to the store, yesterday....needed hinges, a latch....and a Rueben Sammich.....
Maybe later today, I can see about removing the clamps..again, and work on the inside details?


Stay tuned

[bandit571]

Box is out of the clamps used the glue in the floor...top of the box needed to be leveled..

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Ends were a tad too high, and two corners were high than the other two...goal is for the lid to sit fairly flat..

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Box was rocking a bit....needed to get the slips AND the corners all leveled up..
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Same plane as before, since it was already sitting out....Millers Falls No. 9, Type 4
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Looks a wee bit better....

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May trim the lid back just a bit...seems a bit overpowering to the box....We'll see..

Hardware?
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There be a choice of hinges....
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A latch and the brass feet plates....

Sand, fill, sand...stain, hardware install.....see about a tray or two....Boring anybody?