1. PLAN #PartProcessTools and equipmentQuality controlSafety *Aprons must be worn is ALL stages of manufacture Tim e 1 MDF base Mark out on MDF piece Pencil, try square, and ruler Measure out right angles with try square to ensure accuracy and use rule to check all measurements Basic safety procedures 2Cut out base+ sides using a tenon saw.Tenon saw Make sure you do not go over the markings, cut a few mm away from marking lines Basic safety procedures 3Briefly sand edges to sizeBelt Sander Use belt protractor while using belt sander to ensure straight lines. Eye goggles 4Mark out base into thirds Pencil, steel rule, try square Use try square to check all right angles and recheck all measurements Basic safety procedures 5Use router where markings were made Router, G- clamp, Speed clamp Eye goggles + mouth mask 6Briefly file edges made by routerFilesBasic safety procedures 7 Box sides (x 2) measure and mark finger joints to size(on both edges of each piece) Pencil, try square, and rule Measure out right angles with try square to ensure accuracy and use rule to check all measurements Basic safety procedures 8 Cut out finger joints using coping and tenon saw Coping saw, tenon saw Make sure you do not go over the markings, cut a few mm away from marking lines Basic safety procedures 9 Sand out rough edges (using files, after cutting out joint) Files and belt sander Use belt protractor while using belt sander to ensure straight lines. Eye goggles 10 Drill holes on each side 30mm from bottom horizontally Hand drill Find exact center where hole is to be drilled and mark horizontal lines across to find exact center. Eye goggles 11 Box front and back. Repeat steps [7 – 9] for box front and back pieces. -Repeat quality standards as stated above. Eye goggles and basic safety procedures. Drill 2 holes in center of box front and fit handle Pillar drill, screwsMark out where holes are to be drilled. 12 Sides and frond + back Fit & fix the four sides together- Use try square and steel rule to ensure all cuttings have been made accurately and all edges are at 90 o angles. Use belt protractor while sanding to ensure all right angled faces. - 13Eye goggles Use belt sander to level the joint (to not have one piece bigger than the other etc.) Belt sander 14 Acrylic pieces (x2) Mark out both pieces on acrylic piece.Pencil, rule, try squareRecheck measurements using rule and try square- 15 Cut out using coping saw. After cutting to size… - Cut 1 piece 50mm from the edge [horizontally] and 30mm downwards from the top. Coping saw, rule, pencil & try square Leave out a 2-3mm gap away from marking lines while cutting so that it can be sanded to size later. Check right angles at various intervals to ensure correct length and width. Basic safety (hair tied back, sleeves up etc.) 16 Use cross filing and through filing techniques to smooth edges, wet and dry paper and buffer. Files, wet and dry paper and buffer. Use a file to wrap wet and dry paper around to level surface while filing. Basic safety procedures 17BaseGlue base to assembled sides.PVA glue, G clamp Recheck measurements and right angles of assembled piece. - 18 Balsa Box Lid Mark out and cut to size Pencil, try square, ruler, band saw Recheck all measurements before cutting out. Briefly file edges to level - 19Mark out where dowel joint will be placedPencil, try square, ruler Recheck all measurements before cutting out – make a soft indent in balsa - 20Drill 5 holes for dowel jointHand drill-Eye goggles face mask

2. #PartProcessTools and equipmentQuality control Safety *Aprons must be worn is ALL stages of manufacture Time 21 Balsa Lid Fix pieces togetherPVA glue- 22Briefly sand edgesFiles Use appropriate files in comparison to area and length - 23Smooth surfacesGlass paperUse a cork block to keep surface leveled- 24 Acrylic canvas Mark and draw to correct sizes on CorelDraw Computer – CorelDraw software Recheck all measurements before cutting out. Briefly file edges to level - 25Use CNC Laser Cutter to cut out shapeCNC laser cutterRecheck all measurements before cutting out- 26 Measure 30mm from the bottom & make a horizontal line Rule, try square & pen Take acrylic protective sheet off before marking to insure accurate bending Eye goggles face mask 27Bend 45 o Strip heater Place wooden scrap blocks (away from heat line) to keep acrylic in place Gloves (when lifting) 28 Joining Drill 2 holes on each side of ‘Box front’ for locks Hand drill, screws Mark out where hole is to be drilled. Use hand vice while drilling holes Eye goggles 29 Use Cold chisel to cut off 2 mm to place hinges on top side of box back. Chisel, malletCut on waste side so that the cut is not gone in too far- 30 Drill 3 holes for hinges on the top side of box back Hand drillMake indent where holes are to be drilledEye goggles 31Join box lid to box using hingesScrew driver, screws Don’t tighten too much with screw driver so that the holes don’t get loosened. - 32 Assemble all sides and base (not lid or acrylic bits) PVA glueTighten a lot so that it is fixed securely- 33 Clamp assembled piece together – allow to dry and fix Clamps-- 34Use filler to fill any gaps after fixingFiller Don’t use too much so that it doesn't’ come off when sanded 35Sand surfaces after filler driesBelt sander Go near mark lines however not over them so that too much isn't sanded off Eye goggles 36 Wood Finishing Seal all wood pieces –all dimensionsPVA glue mixed with waterCheck at right angles to ensure accurate assembly.- 37Apply first coat of primer on wood pieces.Primer Use thin coats so that paint spots aren't too heavy in places - evenly spray layers Face mask, eye goggles 38Smooth surfaceGlass paper Use cork block to sand evenly so that the surface is leveled - 39 Repeat the previous two steps to give 3/4 layers of primer --- 40Smooth surface again before applying paintGlass paper, cork block Use cork block to keep surface leveled 41Apply paint finish – applying thin layerspaint Use thin coats so that paint spots aren't too heavy in places - evenly spray layers Face mask, eye goggles 42 Acrylic finishing Buffer edges to give a self finishBuffer Make sure all previous lines (from through filing) have disappeared Eye goggles