1. Wood 2 Box Project
Intro

5. Skill Objectives Stock Preparation Joinery Jointer Surface Planer
Table Saw
Joinery
Finger Joint
Rabbet
Dada
Sliding Dovetail

6. Paper Work Due Date: April 20th (4 weeks)
Start Timesheet – 3/20 ‘Planning’
Complete Bill of Materials
Start Procedure Sheet
Very Important because of the NUMBER of Parts

7. Parts List Three Parts List Tables on the Shop Drawings
Upper Right Hand Corner
Drawer Assembly Parts List
Box Assembly Parts List
Box Lid Assembly Parts List

9. 1 BF = W x L x H/144 ALL MEASUREMENTS MUST BE IN INCHES
W  WIDTH ACROSS THE GRAIN
Always 1st Number
L  LENGTH WITH THE GRAIN
Always 2nd Number
H  THICKNESS OF THE WOOD
Always 3rd Number
If there isn’t a 3rd Number it is ¾”

10. Board Feet You MUST use the ROUGH DIMENSION when figuring COST
You need 1” thick material to get ¼”, ½” or ¾” thick stock
Basic Rules of Thumb:
Add ½” to the WIDTH
Add 2” to the LENGTH
Add ¼” to the THICKNESS
DEPENDS ON
CONDITION OF
LUMBER

11. Example Finished Dimension: 3 ¾” x 16” x ½”
Rough Dimension: ¼” x 18” x 1”
W X L X H/144
4.25” x 18” x 1”/144
76.5”/144
BF=.53125
WOOD = MAPLE
X $3.10 = $1.65

12. Remember Use ROUGH DIMENSIONS Double Check the NUMBER of Parts
Double Check you are using the CORRECT price for the Wood
You will have more than 1 wood type

13. How Much $$$$$$$ Wood Available: Soft Maple  $3.10 bf
Cherry  $4.90 bf
Poplar  $2.85 bf
Bubinga  $15.90 bf
Red Oak  $3.20 bf

15. Day 2 -- Stock Selection and Prep
Wood 2 Box Project
Day 2 --
Stock Selection and Prep

16. Safety Tests You must have passed the following tests with a 100%
Jointer
Surface Planer
RAS
Sliding Compound Miter Saw

17. 6” X 36” 6” X 20” Selecting Your Stock Wood is EXPENSIVE
ASK, DOUBLE CHECK, TRIPLE CHECK BEFORE YOU DO ANYTHING!
6” X 36”
6” X 20”

18. Available Wood Soft Maple  $3.10 bf Cherry  $4.90 bf
Poplar  $2.85 bf
Bubinga  $15.90 bf
Red Oak  $3.20 bf

19. TOTAL $COST$ IS DUE TO WHS
Bill of Materials
Bill of Materials MUST be complete
TOTAL $COST$ IS DUE TO WHS

20. STOP Jointing & Planing Joint one FACE and one EDGE
Surface Plane to 5/8” THICK
STOP
Layout your Pieces on your Wood
Like a JIGSAW Puzzle (Best Use of Wood)

21. YOU WILL BE LOSING POINTS FOR MISTAKES!!
Ripping on Table Saw
Review your Layout with Mr. Thuman
Follow Instruction given (INDIVIDUAL):
RIP on Table Saw
Crosscut on SLIDING COMPOUND MITER SAW
Remember to SQUARE UP ONE END!!!
YOU WILL BE LOSING POINTS FOR MISTAKES!!

22. Cutting Accuracy & Time
ACCURACY IS IMPORTANT IF YOU WANT YOUR BOX TO LOOK GOOD!!!
TAKE YOUR TIME AND DO IT CORRECTLY THE 1ST TIME!

23. Basic Geometry IF YOU WANT A SQUARE BOX THIS SIDE THIS SIDE THIS SIDE

24. How Much $$$$$$$ Wood Available: Soft Maple  $3.10 bf
Cherry  $4.90 bf
Poplar  $2.85 bf
Bubinga  $15.90 bf
Red Oak  $3.20 bf

26. Day 3 -- Ripping and Crosscutting Finished DImensions
Wood 2 Box Project
Day 3 --
Ripping and Crosscutting Finished DImensions

27. Safety Tests Andrew Aberts Tera Baker Doug Blank Paul Hassett
Chad Lawson
Billy Rittelmeyer
Mike Shafer

28. Finished Dimensions
Cutting ALL of your pieces will be like a JIGSAW puzzle
Best USE of material
I will review and give instructions to EACH student BEFORE you start RIPPING or CUTTING anything!!
Reduces Mistakes and wasted MONEY

29. Joinery Layout Once ALL pieces are CUT to the EXACT Finished Dimension
Label EVERY Piece
Name
Best Face, Top, Bottom, Left, Right, etc.
Begin Laying Out ALL joinery
Rabbets, Dados, Grooves, etc
Finger Joints, Sliding Dovetails

30. Procedure Form EVERYONE MUST complete the Procedure Form
Each Step needs to be SIGNED OFF by Mr. Thuman

31. Questions!!??

32. Part Name & Quantity

34. Day 4 & 5 -- Laying Out ALL Joints & Labeling ALL Pieces
Wood 2 Box Project
Day 4 & 5 --
Laying Out ALL Joints & Labeling ALL Pieces

35. Joinery Layout Once ALL pieces are CUT to the EXACT Finished Dimension
Label EVERY Piece
Name
Best Face, Top, Bottom, Left, Right, etc.
Begin Laying Out ALL joinery
Rabbets, Dados, Grooves, etc
Finger Joints, Sliding Dovetails

36. Missing Pieces? Make sure you have ALL your pieces
See Mr. Thuman if you don’t
Share between Students

37. Safety Tests
Band Saw
Belt/Disc Sander
Portable Tools

38. Safety Tests
Unless you have passed ALL safety tests with a 100% you will not use any tools

40. Day 6, 7 & 8 -- Cutting Finger Joints
Wood 2 Box Project
Day 6, 7 & 8 --
Cutting Finger Joints

41. Objective Understand BASIC concepts of Finger Joint Layout
Understand use of Finger Joint JIG
Cut Finger Joints using Table Saw

42. Finger Joint
A finger joint or box combing or box joint is a woodworking technique used to join two pieces of wood at right angles to each other. It is much like a dovetail joint except that the pins are square and not angled and usually equally spaced. The joint relies on glue for holding together as it does not have the mechanical strength of a dovetail

43. Use and Benefits Case Joinery Drawers
Anything that needs to be joined at 90 degree angles
Strength
Simplicity
Decorative
Speed
Good in Compression
Good in Shear
Bad in Tension

44. Finger Joint Layout
Equally Divide Width of Work Piece into an EVEN number of Fingers
Depth of Joint equals Thickness of Work Piece
Width of Finger is determined by Strength or Aesthetic

45. Good and Bad
ALL
EQUAL

46. Sliding Jig Holds Stock Vertically Correctly Spaces Finger Joints
To Mill End Grain
Correctly Spaces Finger Joints
This one makes ONLY ½” wide Finger Joints
Any stock used must be EQUALLY DIVIDABLE by ½”

47. Blade Cover
Fence
Indexing Pin/Stop
Runners

48. Stop – prevents cutting through entire Jig

49. Use of Jig Second Cut – previous cut fits over INDEX PIN
First Cut – Stock Against INDEX PIN
Second Cut – previous cut fits over INDEX PIN

50. Completed Joint

51. Questions
Ask Now!

53. Day 9 & 10 -- Cutting Sliding Dovetail
Wood 2 Box Project
Day 9 & 10 --
Cutting Sliding Dovetail

54. Sliding Dovetail Method of joining 2 pieces of wood at 90 degrees
Creates a Structural AND Mechanical Connection
Can only be pulled apart in 1 direction
Tools Needed:
Hollow Chisel Mortiser
Band Saw
Chisel
Square
Hammer

55. 1st Step
Use HOLLOW CHISEL MORTISER to make a SQUARE MORTISE across the BACK face of the DRAWER FRONT
CENTERLINE of MORTISE is ¾” from EDGE ¾”

56. 2nd Step Cut PIN on both DRAWER SIDES Use Layout JIG for SHOULDER MARK
Use Layout JIG for CHEEK Depth

57. 3rd Step Use BANDSAW to cut PIN
Cut from Outside Corner to CHEEK DEPTH mark

58. 4th Step Using PIN as guide, trace the angles onto DRAWER FACE
Use a CHISEL and SLOWLY angle the cheeks of the square mortise

59. 5th Step
Patience
Take you TIME and go SLOWLY
You want it to be a SNUG fit

60. Questions
Ask Now!

62. Day 11 & 12 -- Cutting Rabbets, Dados & Grooves
Wood 2 Box Project
Day 11 & 12 --
Cutting Rabbets, Dados & Grooves

63. Objective & Tools Drawer
Correctly and Safely cut the required Dado, Rabbet and Groove for the Finger Joint Box Project
Review Layout of needed Joinery
Back Saw
Hammer
Chisel
Square
Bench Hook
Table Saw
Drawer
Box Sides
Only

64. Drawer Side (x2) Completed AFTER Dovetail Pin
Need a MATCHING PAIR (Opposite)
Dado: ¼” wide x 1/8” deep ¼”
Rabbet: ¼” wide x 1/8” deep

65. Box Bottom (x4) After Finger Joints are milled Cannot go thru a Finger
Groove: ¼” wide x 5/16” deep

66. Demonstration
I will demonstrate how to SAFELY do these cuts on the TABLE SAW and the using the Back Saw AND Chisel on the Drawer

67. Questions
Ask Now!

69. Day 13 -- Assembling Drawer
Wood 2 Box Project
Day 13 --
Assembling Drawer

70. Materials Needed Sander (Dual Action) Sand Paper
80grit, 100grit, 120grit, 150grit
Bucket of Water AND Rag
Glue
Clamps
Index Cards for Shims

71. Procedure Sand ALL INTERIOR surfaces of drawer parts
Sand ALL surfaces that would be difficult to sand when assembled
BE CAREFUL not to round over and edges or ruin any of your Joinery
NEVER Sand any Joints or Surfaces that will be hidden by a joint

73. Gluing & Clamping Glue and Shim if needed the SIDES to the FACE
Make sure they are SQUARE to FACE
Glue and Clamp BACK into DADOs
Make sure ENTIRE drawer is SQUARE
Measure Diagonals – need to be equal
Clean up Glue with Water
Measure and Fit BOTTOM Panel

74. Center-Line of Clamp ALIGNED with Center-Line of Drawer Side
Make sure Shoulders are TIGHT and Sides are SQUARE

75. Center-Line of Clamp ALIGNED with Center-Line of Drawer Side
Make sure Shoulders are TIGHT and Drawer is SQUARE

76. Questions
Ask Now!

78. Day 14 -- Cutting Drawer Opening
Wood 2 Box Project
Day 14 --
Cutting Drawer Opening

79. Procedure Select your BEST front/back bottom of box
Install in JIG on CNC machine
Run Program
Square up Opening or Round Corners of Drawer Face to match opening
Use a FILE or SANDPAPER on a Block of Wood

80. Questions
Ask Now!

82. Day 15 & 16 -- Box Dry Assembly & Sanding
Wood 2 Box Project
Day 15 & 16 --
Box Dry Assembly & Sanding

83. Procedure Make sure ALL parts are CUT to FINISHED Dimensions
Make sure ALL joinery is COMPLETE
Groove for Bottom
Rabbets
Finger Joints
Dado
Carefully CLAMP ENTIRE box together

84. Check for Quality Everything is Square Gaps or Cracks at Joints
Measure Diagonals
Use a Square
Gaps or Cracks at Joints
Top AND Bottom MATCH
Adjust Finger Joints IF NEEDED
File or Sand Paper WRAPPED around a Stick
CAREFULLY take apart

85. Sand to 150grit Sand ALL interior Surfaces 80grit 100grit 120grit

86. Questions
Ask Now!

88. Wood 2 Box Project
Day 17 --
Box Assembly

89. Materials Glue Bucket of Water and Rag AT LEAST 4 Clamps
Maybe More
Make sure you CLEAN UP ALL glue

90. Questions
Ask Now!

92. Wood 2 Box Project
Day 18 & 19 --
Fitting Drawer

93. Objective
Fit the drawer to the ASSEMBLED BOX so that is slides smoothly

94. Material Glue Tape Pre-Made Runner – 9/16” x 9/16 Bucket of Water
Softwood
Bucket of Water

95. Glue Runners to Drawer Sides
Runners SHOULD be slightly PROUD
Plane to Fit Drawer Opening

96. Questions
Ask Now!

98. Day 20 -- Fitting Dividers and Bottom
Wood 2 Box Project
Day 20 --
Fitting Dividers and Bottom

99. Materials All Dividers NEED to be fitted AND Cut to FINAL dimensions
USE your BOX not the measurements on the Plans
Bucket of Water and Glue
Tape or Thin Scrap Wood to use as WEDGES

100. Procedure

102. Day 21 -- Fitting Hardware
Wood 2 Box Project
Day 21 --
Fitting Hardware

104. Day 22, 23 & 24 -- Final Sanding and Finishing
Wood 2 Box Project
Day 22, 23 & 24 --
Final Sanding and Finishing

105. Last Day to Work IN Class
Project Due Today
Last Day to Work IN Class
After School Work
Mon, Wed, Thurs, Fri  2:30 to 3:00
Tues  2:30 to 4:30

106. Unit Test
Tuesday May 1st

107. ALL QUESTIONS FROM WARM-UPS
What’s On the Test?
Stock Prep
Four-Square
Joinery
Finger Joints, Dado, Rabbet, Groove, Dovetail
Tool Use
Jointer, Planer, Table Saw, Radial Arm Saw, Sliding Compound Miter Saw
Measurement
Adding and Dividing Fractions
Reading a Ruler
Reading a Machine Scale
ALL QUESTIONS FROM WARM-UPS
TEST IS OPEN NOTE