Creative Woodworks & crafts 2000-08, страница 47

Step 8. Cut the dadoes which will receive the panels in the front, back, and side pieces 1/4" from the edge and 1/4" deep (see the Dado Detail Drawing found in Full Size Pattern Section No. 1). Make them as wide as your top panel and bottom require (it should be 1/4" +/-). We normally apply a coat of Watco natural Danish oil to the exterior surface and allow three to five days for it to cure prior to gluing up the box. This serves two functions. One is that any glue smeared on the exposed face will be easier to clean up, and two is that we like the color it brings out of the wood prior to finishing. Do not apply oil to the surfaces to be glued.

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Step 12. We used circular hinges that are set into a recess bored with a 1-3/8" Forstner bit on our box. Good quality hinges are a bit expensive, so feel free to use hinges of your choice.

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Step 13. As you can see, we elected to use an alternate method of mounting the lid stop. Because the box is small, the additional thickness added too much bulk to the appearance, and also required the use of No. 6 x 3/8" screws rather than the supplied No. 6 x 3/4" screws. Be sure to bore pilot holes for the screws to reduce the risk of splitting the wood.

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Step 9. Assemble the box. We prefer to cut the splines so that they fit inside the top and bottom panels in a box this size. Insert short pieces into the top and bottom of the assembly to continue the effect. This way you don't have to notch the raised panel or the bottom piece in order to insert a full length spline. This is the easiest way I know to assemble these joints.

Step 14. We routinely use DonJer "Suede-Tex" Flocking when we elect to line the interior of boxes. It is neat, does not require precise fitting, does not reduce the interior dimension of small boxes, and makes a very nice appearance. Be sure to follow all product instructions. Tape the areas you wish to protect and paint the undercoat adhesive on all areas to be flocked.

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Step 10. Check that the box is square by measuring diagonally, and make any adjustments with the clamps before the glue sets up.

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Step 15. We do not have a flocking gun, we just dump some into the box and shake until all intended surfaces are coated, then dump the excess onto a large piece of clean newspaper and save it to reuse. Once the undercoat adhesive has cured, gently vacuum any remaining excess and then finish the box as desired.

Step 11. Cut the lid free on your table saw. Clean up the saw marks with a file or sandpaper.