Project is a small open tool
tote with a dowel handle.
Design
Wood Selection
Milling,
Carcase Assembly
Finish Application
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A Sketchup model of the basic layout.
Colors shown are used for clarity...wood will
actually be different.
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Sides will have a through 3/8 x
3/8 groove that will exit between tails.
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The ends will have 3/8 x 3/8 inch
stopped grooves.
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The inside of the box will have
the groove that will let in the bottom blank.
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There is a 1/8 inch rabbet
around the interior lower edge of the bottom plate.
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This is an alternate angular end
plate.
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This is an alternate curved end
plate.
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Wood Selection
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The wood in this project will be poplar
purchased down in Star.
The planks was pulled out of deep
storage in shop attic.
This plank started as 4/4 lumber...we
jointed, planed to thickness.
Ripped and chopped to blank size.
The bottom of the tote will be .50 inch
Baltic birch ply, and the handle 1" dowel is oak
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Joinery and Assembly
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Backside...rebate with skew block
plane... ~ 1/32 inch. |
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Cut the tails with Toshio Odate
dovetail saw, ~1/64 plate.
Used the 1:4 Barron guide. |
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The pin board was placed into the
bench vise...height adjusted to plane height.
Tail board was placed atop pin board...the rebate kept it
indexed appropriately. |
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Offset of the saw plate (and the
set) was determined using a Tite-Mark
The blade is listed as 1/64 inch or .015625 inch |
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As part of the new OCD
process, the tail board was offset to the left then the kerfs
were marked on the right side of the pins.
When the offset was moved to
the right, the kerfs were marked on the left sides of the
pins.
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We later determined that that a
.013 leaf from the Glen-Drake offset gauge worked better for our
alignment purposes... |
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First efforts to scribe the
line...we used the Toshio Odate...the saw was placed into the
kerf and was used to scribe a line into the end grain of the pin
board.
There was an issue that the kerf was not scribed all the way
across the board... |
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We then stumbled onto an improved
model...a Chestnut Tools veneer saw that we tried and like...it
is now called the Kerf Scribe Tool. |
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After the kerfs were scribed, the
pins were cut with Toshio Odate |
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Waste was cut out with Knew
Concepts coping saw, 12.5 tooth, skip blade. |
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laying out end plates |
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cutting at bandsaw |
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the groove for the 1/2 plywood
bottom plate was done at the router table with the undersized
plywood router bit (31/64)...the sides were through grooves
hidden in dovetails
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the end plates needed stopped
grooves... |
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the grooves and dovetails... |
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after dry fit of dovetails,
we ran the sides and end plates through the drum sander
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...the one inch holes for the
handle were drilled 3/8 deep...final dry fit...ready for glue
up
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glued and clamped off...as
always, you can never have too many clamps |
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after pulling the clamps, the
dovetail ends were made coplanar in a variety of ways...jointer
where possible, flush saws, chisels, hand planes and
sanding...there were a few gaps between tails and pins that were
created early in our OCD training... |
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these caps were closed off with
some glue/sawdust mix plus final closure with oak shaded
TimberMate |
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After final sanding by hand at
220x,
applied my shop mixed wiping varnish
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a couple of coats and it looked
fine |
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in use |
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