Creative Woodworks & crafts 2005-06, страница 60

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INSTRUCTIONS

All of the wood needed for the project is listed in the Bill of Materials. The sizes listed for the cherry box parts (A through D) are working sizes, which will be trimmed to finished sizes after the contrasting wood strips are attached. Feel free to use the woods of ycur choice for any of the pieces (e.g., the sky and foreground of the deer inlay can be different colors if you wishj. Refer to the photographs and illuslrations lo understand where the various parts are located and to observe how the contrasting strips flow through the entire project.

Making the box

Start by cutting all of the box pcrts [A, B, C and D) to working sizes as described in the Bill of Materials. Note: Take time to check thct your tools are accurately adjusted tc be cutting square end true.

Next, make the 12" lengths of contrasting strips. Place a light strip between two dark strips, with an even coat of glue between each strip, and clamp together unlil dry. Then cul these into smaller strips cs follows: four strips 6" long, four strips 1-3/4" long, and four strips 2-1 /4" long. Set aside.

It is very important to cut all of the parts of the box accurately so that the contrasting strips will run evenly from Ihe lid, down through the front and back panels, through the base, and down through the feet. Take your time so as to accurately measure' and cut the parts. The center sections of the lid. the front and back panels, and Ihe base should all be cut at exactly 6-1/2" long in order to ensure that the contrasting strips are all exactly the same distance apart.

Start with any box part. Measure and locate the center of the length of the material. From Ihis poinl, measure 3-1 /A" in both directions and make marks to use as guides tc saw off both ends (this will maintain wood grain patterns across the pcrts). Repeat the measuring procedure until you have mcde marks on the lid, froril arid back panels, and the base. Before cutting, align the parts together in order to check that all of the center areas are marked to be sawn off at the same lengths. Again, be sure that your saw is set up tc cut square, then go ahead and cul Ihe parts. After cutting, re-check each and every piece by placing them beside each other to see If the center (6-l/2"-long| sections are all exactly the same length. If they-are not, trim them so they are all the same. (Itwon'l mailer if Ihey end up slightly less than 6-1/2" long, provided they are all cxactly the same length.)

Once you have the center sections cut to size, dry fit the contrasting strips on the ends of Ihe cenler sections and place the end pieces in their proper locations as well. Repect the procedure to check that the sections for all of the parts will fit perfectly together. You may need to use a disc sat'der (or equivalent lo slraighten edges and adjust the fit. When you get everything tc line up just right, work with each part and apply an even coat of glue to the joirts between the contrasting strips and the mating pieces. Carefully clamp logelher, paying close cMention Ih.at all surfaces remain flat. Allow to dry.

After all of the parts have dried, it is time to measure and trim them to their finished sizes. (Always keep in mind that you waril those conlrasling sltips lo line up!) Slcrt by trimming the front, back and end panels to be cxactly Ihe same height (1-1/2"). Trim the two end panels to be exactly the same length (5"). Bevel their ends 46° to form the mitered corner joints.

Next, measure the front panel to be 9-3/4" long. Place Ihe front pane! on top of the rear panel, and align their

contrasting strips. Mark the ends of the rear panel to be trimmed off exactly, the same cs the front panel |9-3/4" long) to ensure that they will line up during assembly. Trim the parts to their finished size, and bevel the ends 45" to form the mitered corners.

After trimming all four sides of the box to size, dry fit the corner joints and make cdjustments as needed to get the box to fit squarely together. Set aside.

Next, trim the lid and base parts to size. {Again, you v/ant to pay attention to those contrasting strips.) Refer to the pattern for the lid as you measure and mark it to be trimmed to size. Before cutting it, plcce the front panel on top of the lid and check to be sure that the conlrasling strips will line up after trimming. Adjust the marks in either direction as needed. Also, before cutting, place the base part under the lid, and line up the contrasting strips. Mark the base to be trimmed off to match. Then, double check everything and gc ahead and trim the lid and base to their firished sizes. Set these pieces aside. Measure and trim the four feet to their finished size by referring to the full-size pattern.

Locate the pattern (B) for the base and lid. Make two copies, thus saving the origincl for future use. Use sprcy adhesive to temporarily adhere one copy of the pattern to the piece of wood for Ihe base. Line up Ihe palletn wilh the contrasting strip. Use your scroll saw to cut the notches around the outer edges.

Temporcrily adhere the other copy to the piece of wood for the lid. again lining up on Ihe conlrasling strip. Use your scroll saw to cut the notches around the outer edges and the 4-l/8"-Dia. opening in the center. (Take your time to saw out this opening as carefully as possible,) Note: You will see the buck side of Ihis opening when the lid is open. My prototype didn't turn out as perfect cs 1 would have liked, so I chose to hide it by placing a photc of a "woodsy" scene over it.

Deer inlay

The circular opening in the lid will hold the deer inlay. This inlay is designed to be recessed approximately I/O" deep-within Ihe opening. To accomplish this, you can saw out the opening and save the cutout piece to reinstall behind the deer after it has had its thickness reduced to 1 /4". (In this case, you will need to drill c very small hole direclly on Ihe culling line lo use Tor Ihreuding the blade, and blend the hole into the kerf of the saw blade as you complete the cut.) Other options are to carefully cut out a separate l/4"~thick piece of wood tc insert into the back of Ihe opening, or lo make and inserl a 1/8" piece of wood behind the deer with a 1/8" Plexiglas mirror installed to fcce the inside of the box.

Make the pieces for the deer inlay by stackirg and sawing Ihe different colors/species of wood simuilaneous-iy. Start by carefully sawing the circular outline as smoolhly cs possible. After doing so, wrap pieces of masking tape cround the edges of the circle to hold al! ir. place. Drill a small blade enlry hole wilhir Ihe deer's eye arid cul it out with a 2/C blade. Then use this same small blade to saw the individual parts out of the circle by sawing ir from the outside edge. Save all of the pieces, including the very small piece localed be I ween Ihe deer's rear legs, for reassembly. While the rest of the picccs arc a!ladled lo a backer during assembly, the eye can be filled in with a mixture of walnut sawdust and glue. For now, just plcy with putting togelher Ihe different combinations of wood colors in various ways until you find the combiriulion thai you like best. Then just set it aside for a while.

BO • Creative Woodworks S Crafts Jure 2005