latest box design

since I'm still not bored with my latest box design, I share it again, after adding one more coat of oil, a lining, and felt feet. this will be sent to Fine Woodworking to be shared with readers as part of a router bit review.

testing router bits...

I have been asked by Fine Woodworking to do a small box to demonstrate the use of the tiny router bits, so I am making a small Greene and Greene styled box with box joint corners. First (after resawing and planing the stock to an appropriate thickness) comes the use of the table saw sled to cut the parts to exacting lengths. This requires two settings of the stop block.

Two settings of the stop block gives material for two boxes.

Next, I use a sled on the table saw with a guide pin to cut the finger joints. as shown in the images below. Now the box parts are ready to test router bits.

This technique of cutting box joints becomes easier with practice. Knowing just how tight to hold the stock against the guidepin helps. If you apply a lot of pressure one time, but simply just touch lightly the next, the distance between cuts can be distorted leading to a poor fit between parts. Practice, practice, and practice.

Use a  5/16 in. box joint blade and 5/16 in. drill bit as guide pin.

Trial fitted finger joints... a tight, but near perfect fit.

Sander holder

A reader, Roger, sent this idea for holding a sander inverted for sanding small boxes. It is simply a board, some zip ties, and clamps.