Today is going to be fun. Remember
that jig we made last week? We're going to use this to show you how
to make a beautiful walnut toolbox check it. I got this beautiful piece of
walnut from my friends at Kencraft. You should check them out. This guy
is 10 foot long, 11 inches wide. I've already roughed mark
where all my pieces are. I have to cut it down to a smaller size
because it doesn't fit in the shop and I can't wiggle it around. And then we're going to run it through
the planer and get it down to three quarter inch thick. So now
that I've got that planed down, I'm going to rip this to width. I'm going to do one cut for all the
sides of the box and then another cut for all of the lids. So now over here at the miter saw, I'm going to cross cut the sides and
the ends for the box and the top.
I got my stop set up over here. This piece goes with this piece. This
piece goes with this piece and so on. I want to mark these. So if this is
a side piece, the lid will match. Now that we have our eight pieces
cut for the box and the lid, we're going to use this
jig that we made last week. We have to mark the top of all of
our pieces. This is really important. Next thing we need to do is set the bit
height and it needs to be just beyond. If you want to see how this box joint Jig
was made, check out last week's video.
We go over how to make it and then how
to use it. So now that we're all set, we're going to let Dan do his thing. You can do this at the table saw. In fact
it's actually easier at the table saw, but then you have to use a dado stack. In some areas you don't
have access to that. So you could do it at the router
table or you can make this jig. So the next thing that I have to do is
I have to route a dado on the sides here for the handle. That's
going to go in the middle. Now I'm over here at the table saw with
my sled and a flat bottom grind blade that leaves a nice
clean cut on the bottom.
I've got two stops set up so I can take
my piece of wood and go in between those and just kind of nibble away
until I get the dado that I want. You can use a dado stack. I don't want to, you can also do this over at
the router and I don't want to so now we're going to cut a groove for
the bottom piece here and we're going to do that at the table saw I have
Dave. Oh, this is my favorite scene. Love this. Yeah, yeah. They don't make
movies like that anymore. High fives. So now we're going
to cut a groove in the bottom.
We've got our flat bottom
grind blade in the table saw. I got it set to about half the height
of the thickness of the walnut and we're going to make a pass on all the pieces. We're going to nudge it over and make
another pass until we get that dado. A quarter of an inch thick. Now cutting all the way through is
going to leave a little hole there. We're going to plug that
later. To avoid that, you would do this at the router table
and you would plunge and you would go so far and you would pull up. But the problem with this is my fingers
are a little bit too small and there's a chance that they'll break. So we're just gonna cut all the way
through and plug the hole later. One pass, I'm nuged my
fence over a little bit.
And we're going to do a second pass here. So now that we have all of our
pieces cut for the box and the lid, it is time to cut the bottom.
That's going to fit in this groove. So we're gonna use the remaining
piece over here at the miter saw. We're gonna rough cut it. Then we're going to rip it and then we're
going to resaw over at the bandsaw and then we'll plane it down to its final
thickness. So it just fits in that groove. There we go. I usually make the bottom pieces out of
plywood because it doesn't expand and contract. But I wanted this
to be completely walnut. So now the trick is to cut
it down so it fits in there. The length of it can touch the ends, but this wood is going
to expand and contract. So I need a little bit of space and that
has to have some wiggle room in there so we can change over the seasons.
That's going to work. There's a little bit of place
so it can expand the contract. It's actually in the humid
summer season right now. So in the winter it's actually
gonna. The lid is slightly different. It's not going to take up the whole bottom
because it needs to have room to slip over the handle. So I needed to
rip this down into two pieces. I'm not gonna put any
glue on the bottom panels. I'm only going to put
glue in the finger joints. That way the panels can do their thing
over the seasons and move around and whatnot. So this doesn't
take a lot of glue. Now is a good time to sand
all the inside pieces. This is where having a nice
ice pick in the shop helps. Box joints just go together square. That's what I'm talking about Dan,
what am I talking about? This? This is what I'm talking about.
while those two assemblies are drying, I'm going to work on the handle. I
don't have any walnut wide enough, so I need to cut two pieces and glue
them together and we're going to do that over… This is a pretty wide piece of wood
and it's going to want to expand the contract over the seasons. So if
I only put glue here and here, it will allow movement
and it can go up and down. I'm also gonna put a little
bit of glue along the bottom. You had to sand the edges here and round
them over to get this to fit on there nice.
But it does look at that.
This also goes to this way, two more pieces to cut and there going
to be two little little walls that are going to go right inside here. So when
you pull this up, screws or whatever, don't fall into that hole. Glue this in. Three more things to do in reverse
order. We've got to put finish on there, we've got to sand it and
we've got to plug these holes. What you could do is cut a
couple more little fingers, break them off and then
stick them in there. I got real lucky happen to have a
piece of scrap that fits in there.
If you have any gaps and you can
stick a little glue in there, kind of rub it in. And then
this is dust for my sander. I've only been sanding a walnut
since the last time I emptied that, so I can just kind of mix that right
in.I want to chamfer this bottom. So there's a nice shadow line there and
then also chamfer the bottom of this. Got that nice champer on there. It gives
it a little bit of separation there. I'm using this, this Odies oil. I get
asked all the time, do you like it? And the answer is I love it,
but I don't recommend it. I love it because it allows me to just
do one coat and then move on and I don't have to wait for anything to dry. I can just kind of buff it out
and then move along with my life. I wouldn't put it on furniture. I
don't think it's that protective. So I'm going to have plans for this,
but I'm going to remove an inch, maybe an inch and a half.
it's too tall is these are too deep, so I'm gonna make this
a little bit shorter. I will have plans for sale on
my website, makesomething.com. All right folks that wraps
it up. As always, be safe,
have fun, stay passionate, and make something..