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BillBrush

A poor substitute for a boat, but a project still

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With my tolerance for tv at "overload" due to all the political "news" I was desperate for a project to get me away from the tv and computer.  So I started cleaning the garage.  That led to sharpening tools, since I hate using a dull chisel or plane.  That led me to conclude that I needed a new box to store my whetstones in.

So began, Da Box Project.

First, the current box, so you can see why it needs replaced.

http://picasaweb.google.com/lh/photo/lQtopqItb0i9hf66P9RE0Q  (Apparently the "Add image" link doesn't like me, so I'm having to use links.

The box ends, showing the dados cut for the partitions.  I pooched one corner, so one of them is assymetrical from the other three, but it's about function with this project.  This was my first go with oak in about 20 years, and I had forgotten how nicely it works.

The http://picasaweb.google.com/lh/photo/G2Cr49j--G8KxYKW2Hnnjgpieces.'>http://picasaweb.google.com/lh/photo/G2Cr49j--G8KxYKW2Hnnjgpieces.

The box interior partitions.  I designed these on graph paper, then prototyped them with foamcore once the shell was done.  They will hold up a tray for a 2nd level of storage once the box is assembled.  The tray isn't started yet as I will build it to fit the assembled box.  There is a compartment for each of my stones, plus a couple spares.

http://picasaweb.google.com/lh/photo/G2Cr49j--G8KxYKW2Hnnjg

Dry assembled box, stones, and oil.

http://picasaweb.google.com/lh/photo/tq3Jsnz9exd_62vxOBWhmQ

Dry assembled box, interior shot.

http://picasaweb.google.com/lh/photo/jo_Gm1f4s4nY9Ia84y_uvQ

Dry assembled box with lid.

http://picasaweb.google.com/lh/photo/g3I9y1dxetf_gIvVF6UZrw

Tonight the pieces are downstairs being Danish oiled (Watco.)  The interior is getting black walnut and the shell is getting natural.  I'll probably take more pictures as I go through the project.  The dimensions on the box are 8"x6 1/2"x6"  (LxWxH). 

My current conundrum is the latch/handle.  I would like to make some sort of clever handle-latch combo that locks when the box is picked up, but I haven't come up with a design I think I can both build, and looks sufficiently reliable.  I'd also like it to be flush with the top when not in use so i can stack stuff on top of it.  A lot of criteria there, so I may have to compromise.  :)  The tray is going to have foam on the bottom of it so it holds the stones firmly in place when everything is closed up.

All in all it's far from perfect but it has been really nice doing something out in the shop again.  The kids have also had a good time feeding the wood burning stove  and asking Dad a whole lot of questions about "What does this do?"  The smell of oak sawdust brought back a LOT of memories.  :)

Bill

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Bill- the "add Image" doesn't work for anyone. You have to use the "additional options" Click there and it'll let you browse your harddrive and add images, up to 256k (total) and 6 images. They will not show on preview though.

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  Cool project.  I'm always thinking about making various boxes to hold various tools but I never seem to get to the point of making sawdust.

  What are you going to use the Nike box for now?  ;)

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   Cool project.  I'm always thinking about making various boxes to hold various tools but I never seem to get to the point of making sawdust.

   What are you going to use the Nike box for now?  ;)

The Nike box has so much honing oil impregnating it I think it's going in the wood burning stove.  It ought to burn for about a week.

Worked on it last night, and decided I didn't like the way the edge grain of the partitions looked so I cut some strips out of some scrap I had to glue to the edges.  The scrap is some unknown yellow wood, so it should look nice in contrast to the dark.  For some reason I think it was called yellowheart at the store, but I'm not positive.  Ah, Google to the rescue, yes here it is:  http://www.thewoodbox.com/data/wood/pauamarelloinfo.htm

The curves were a bit challenging, but I set the plane to extra thick and muscled it through for some thin strips.  Tonight I should be able to get some Watco on them (Natural) and see if it works.  My wife is of the opinion I've lost my frigging mind for doing all this on a box for whetstones.  :)  She just doesn't get it.  ;D

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Ok, looks like the trim is looking good, and I am going to sleep on it, then glue it tomorrow, and then start working on the outside of the shell.

Here's a pic of the assembled box (dry fit).

There are more pics of the exploded view, and a closeup of the trim.

http://picasaweb.google.com/bbrush/StorageBoxProject#

It's coming along nicely up to this point, but I'm going to have to get off the dime and decide on my lid catch.  I'd like to be done before Monday. 

post-1622-12949767877_thumb.jpg

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Looking good - I can't wait to see the finished beast.  One day I'll post the pics of my portable fly-tying box but first I have to get off my behind and cut some wood (I'm such a wannabe these days.  Sorry.)

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Looking good - I can't wait to see the finished beast.  One day I'll post the pics of my portable fly-tying

Please do- I'd really like to see that. Does it have space for buck tails and other deer hair?

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Bill- the "add Image" doesn't work for anyone. You have to use the "additional options" Click there and it'll let you browse your harddrive and add images, up to 256k (total) and 6 images. They will not show on preview though.

Thanks, Charlie.  The "add image" service seems to work sometimes, but its been down more than up, so I have disabled it again. 

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Well while Konrad was out sailing I was hip-deep in projects.   Among which was "Da box."   I was able to get the latch fully fabricated over the last couple days despite managing to solder the piece I was using to position the barrel on the face plate to both the face plate and the barrel.  The barrel was broken getting that out, and I almost had a disaster on my hands.  Despite that I was able to get the latch finished and today I cut the mortise for it.  A little polishing with the Dremel tool and I test fit it.  During the test fit I snapped off one of the brass screws holding it in, and I thought I was going to have to redo the lid.   :o  A little chiseling, and some needle-nosed pliers removed it though and I was back in business.  As of the end of tonight, the shell is assembled, sanded, and oiled.  YAY!  All that's left is making the tray, which I started before I came in to apply oil.

Pictures below.  The brass face plate isn't perfect, but it's hard to get a really flat face plate when you're working with hand tools, and it's very thin brass.  Still I think it looks ok for home-built.

Hopefully by Wednesday I'll have the tray finished and I can count this project done.

Pics in order:  Fully assembled and glued shell,  Latch face - test fitting,  Latch bolt,  shell complete - with latch installed.

post-1622-129497678926_thumb.jpg

post-1622-129497678931_thumb.jpg

post-1622-129497678937_thumb.jpg

post-1622-129497678942_thumb.jpg

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Well tonight was good.  I have the tray fabricated and glued up.  Tomorrow will be a final sand and trim and then finish oil.

I decided the butt joints on the tray sides weren't going to work so with some gyrations with the table saw I splined the joints.  Cutting the splines was tricky with the tablesaw since they were only 7/16x1/8x1, but I got it done and it looks good.  I used some scrap redheart for the spline so it should look nice once it has the finish on it. 

Some pictures:

post-1622-129497679451_thumb.jpg

post-1622-129497679455_thumb.jpg

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Yep, I actually feel a little guilty that it's such a nice piece of work and I'm going to use it for a very utilitarian purpose.

As of about an hour ago it's finished.

Made some brass springs to hold the tray down when the lid is shut, and cut some foam to hold the stones firmly.  The tray got the finish oil a few hours ago and I definitely like the looks.

So to close out this minor threadnought, here are the last pics.

If you want to see them all, you can go here:

http://picasaweb.google.com/bbrush/StorageBoxProject#

post-1622-12949767946_thumb.jpg

post-1622-12949767947_thumb.jpg

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   Great job.

   I bet that box won't be reassigned to other duty.  The sharpening stuff fits too well in it.

Well it fits like it was made for them; because it was.   :)

I drew out the plan in 1:1 scale on graph paper and fit plan to the stones as close as possible.

Now I just have to clean up the mess.   :D

Best lesson learned during this build:  Double-sided carpet tape (duct tape style) is an AWESOME clamp.  I used it for everything from holding down the shell pieces to holding the tray sides to the jig for cutting the splines in the end grain.  I even used it to hold the sacrificial fence to the rip fence.  In some cases I needed a piece on each board, and then joined them with the double adhesive.

Maybe I need to build something to hold some of my other tools.  Something like the attached picture maybe.

If you've never seen video of that chest it is just unbelievable.  Here's some more shots of it at the Smithsonian site.  http://americanhistory.si.edu/collections/toolbox/piano.html

post-1622-129497679482_thumb.gif

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