BUILD A BOX WORK INSTRUCTIONS

Instructions:

Creating my personalized box.

Approximate work time 7hrs 15min

 

Cost Analysis:

Not part of cost

• All hand held and table tools
• Pencils

Part of Costs

• Wood cost: $10 per plank $50
• Paint brush $4
• Sand paper $12 Pack
• Wood stain $23
• Pay myself $19/hr average apprentice carpenter hourly.
• Screws $43
• Labor Cost: $133

Total: $265

Tools:

• corner clamp
• table clamp
• drill
• ⅛” drill bit (for pilot hole)
• Torx head driver
• 3/8” drill bit (For countersink)
• hand held saw
• Dremel with rotating cutter head
• Band Saw
• Table Sander
• Planar
• Miter Saw
• Router
• 90 Degree Angle Router
• wood stain (Cherry)
• Screws
• Mallet
• Tape measure
• Pencil
• Cherry Stain
• Paint Brush

Materials:

• 9 x 14.5” long pieces of 1×4 lumber
• 6 x 12” long pieces of 1×4 lumber
• 4 x 10-11” long pieces of 2×2 lumber

Steps: 

Get the long planks of 1×4 wood from the wood shop and measure one piece of wood at 16 1/8^th inch and one piece of wood at 12 1/8^th inch then mark with pencil. Measure one 2×2 long piece of wood and measure at 12 1/8^th inch. Do the same with the 1×4 layered wood for the base of the box. Place these pieces on the miter saw and cut each on the side of the mark made that is closest to wear the tape measure was anchored at.

 

Once one of each are cut use those pieces as templates for the rest of the lumber. Need to make 6x of the long pieces 6x of the short pieces and 4x of the 2×2.

Once these pieces are all cut out get the pieces of 1×4 planks and set of the planar for one pass on each sides of each piece of wood.

One direction until wood chips come out of the planar then rotate 1/4^th rotation. (Ensure to rotate back 2 ¼ rotations after each completed planar use so the wood is the same thickness.

To start I assembled the four sides of the box out of the 1×4 lumber. To do this I used the corner clamping method demonstrated in class to secure the sides. Since the box is 16” deep and 12” wide, start by taking two pieces of 1×4.

 

Line up the ends of two sides of the box in the corner clamp. Use the regular clamp to hold onto the table. Using the corner of the table is most optimal as there are most angles that can be access from this position.

After placing the corner clamp in line I used the countersink method with a 3/8^th drill bit about ¼ inch into the wood then used a pilot drill bit 1/8^th to make room for the screws. Using the Torx tip and torx screws I screwed together 12 joints with 24 screws total. Many mistakes were made here with the pilot drill bit here.

 

 

 

Once the frames were made, I took one frame and used the clamps to hold it down. Using the hand saw I approximated the center of the wooden plank and made a long cut that would the vertex of the parabola of the handle. Once this was made, I used sequential cuts that were shorter and shorter to shape the handle. Using the mallet I hit out the parts that were cut to make a surface to sand down. (This was the most fun)

(Failure of hitting out the handle. A knot was in the cut and the whole part come out)

(The fix was to screw back in two places in order to keep the integrity of the part.)

Once the handles were cut out the table sander was used to achieve a good shape and to rid of spurs.

The components are now all together in a frame. Acquire the 1×4 Layers of wood and screw into the bottom of one (not the handle) frame using the same countersink method and space the screws to evenly distribute the weight. 4 screws for each plank. 12 Screws for this step. (Notice the boards are lifted from the surface and not flush. This is a deviation.)

 

Once this bottom frame is attached to the bottom slats, I added the four 2×2 to the inside of the frames and used two screws for the bottom of the of the 2×2. Using the clamps and rubber mallet I shaped the 2×2 to fit the frames in order to fit them within the four corners. Sequentially I used 2 screws in each of the frames into the 2x2s. Screws total 24.

 

In order to achieve a consistent look, I used 1×4 planks to separate the frames. Additionally, I used a level to ensure that the frames were all lined up.

Once the frames were all placed on the 2×2 and into a crate there was extra material on the 2×2 so I used a handsaw to cut them down. Then back to the table sander to get rid of harsh edges.

The whole assembly goes through the table sander once again to rid of hard edges. The majority of the post processing is the orbital sander on the box. This box is soft to the touch on all surfaces and was approximately 1 hour of sanding.

After the orbital sanding I used the cherry wood stain with a paint brush and applied a stripe pattern on the box and put my handprint in the middle of the box for that artistic touch. Let dry and complete the build!

Finished product!