Popular Woodworking 2001-08 № 123, страница 50

Popular Woodworking 2001-08 № 123, страница 50

People will wonder how you managed

to build this multi-faceted shell.

Is it carved? Assembled from individual parts? As with many amazing things in woodworking, the answer is a router with just the right bit.

Almost every project requires a special tool - one that is occasionally pulled out of the back of a cabinet drawer or purchased specifically for the project. In the case of the Box Turtle, the reverse was true. A tool led to a project. I saw an unusual 120° v-grooving router bit in a catalog (Eagle America) and couldn't help but wonder what anyone would do with it. The Box Turtle is an answer.

Begin your box turtle by preparing laminated stock for the shell. You will need 3/s"-and ^"-thick material no less than 51/2n wide. For the prototype appearing in this article, I stacked laminations starting with a base of 3/s" walnut, followed by 1/8" maple, topped with 1/s" walnut. This 5/s"-thick "zebra" plywood can be made of any contrasting woods. In order for the stock to be manageable in the router jig, refer to the cut sheets for layout of all the shell components on three 12" lengths. Since the width of some of the pieces is 51/4", it is important to keep the long edges of the laminations aligned during glue-up. To combat the inevitable sliding that occurs during clamping, I start with 13"-long strips, drill 1/4" holes at the corners, and insert short lengths of 1/4" registration dowels. My "press" consists of eight pistol-grip clamps, with two small bar clamps thrown in for good measure, and a 1x backer board.

by John Hutchinson

The Box Turtle marks John's third appearance on the pages of Popular Woodworking. For those readers that have not attempted his Secret Toad Box or Sea-D Otter, we hope that this third project will be the charm.As we went to press, still more life forms were clawing their way up from the ooze of John's fertile mind. Stay tuned. You can contact John at JTHutch1@aol.com.

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To make the shell, first make your own plywood. I used alternating layers of walnut and maple, though any contrasting woods would do nicely (lacewood and maple perhaps?).As with veneering,you need to make sure you use enough glue and enough clamps. Apply the glue with a stiff-bristled brush and clamp it up with whatever you've got. Be sure to clamp the middle.

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