Popular Woodworking 2007-11 № 165, страница 81
The bands are used to trace the oval for both bottom and top. Use a mechanical pencil for line accuracy. The direction of the fingers is determined by how you lay the band on the board. Most Shaker boxes point right, but whether right or left, both top and bottom point the same way. Cut the oval then sand up to the line. For this project the edge is slightly beveled to aid in a tight fit. About 2° seems to work with the thick bottom board. The drawing is on the inside surface, so slightly lift the disc sander table to achieve the 2° cork effect. Lift the disc sander table until Vs" shows at the heel of a square laid against the disc. If your disc table will not go beyond 0°, try taping a scrap of V16" veneer to the table to support the outside edge of the oval board when sanding. Engage the oval board into the front face of the band, then work the back into place and push down with hand pressure. This will avoid catching and tearing the feather end. When flush all around, sand flat. The board is held in place with wood pegs (toothpicks cut in halfwork well) in holes 5/64" drilled V2" deep every 2" around the perimeter. Holding the drill accurately to avoid breaking through the surface of the board is a challenge. Without making a special drillingjig, you can tape a strip of Vi6"-thick x V2"-wide veneer to your bench. Chuck the 5/64" drill with 1" of the bit exposed. Photo 16 shows how the veneer will guide your drill bit for depth and placement during this step. I suggest you try a scrap of the top board to be sure it is working as you expect. The wood pegs are tapped firmly into the holes before being snipped off and sanded flush. Any gaps in the j oint where board meets band can be filled with carpenter's glue wiped into the crack and sanded immediately so the wet glue line is filled with sanding dust as well as removing all traces of glue from the surface. Part III: Music Works and Finishing After all box parts are complete, the box is sanded. Oval boxes are traditionally left unfinished on the inside to avoid pent-up odors from oil or varnish. Any finish you use for other projects will work for your box. Cherry will achieve its own patina if left with a clear coat rather than stain. The music works are attached with four small screws. Center the winding stem in the hole and locate the screw holes with a nail or sharp awl. Children and adults too find the music box fascinating, especially hearing the sound amplified by putting the top on and covering the music works. The message of the Shaker song is one to match the beauty of the box - " 'Tis the gift to be simple." PW ^ Tap tooth-I J picks into the holes. If securely in place, no glue is needed. Snip off and sand flush. O The music I \J works is screwed into the box after all sanding is complete. Shaker boxes are normally left unfinished inside while clear coating the outside. Four small screw holes are centered and drilled if a hardwood board is used In softwood, only an awl point is needed. The stem will center in the hole. The 3/a" -thick bottom board allows it to sit flat on the table. fohn is the founder of The Home Shop (ShakerOvalBox. com) in Charlotte, Michigan, which produces and sells supplies for making Shaker oval boxes. His shop was featured in Great Woodshops, in the August 2007 issue of Popular Woodworking (#163). Supplies Any project is the conclusion of a variety of sources. The author acknowledges his debt to two individuals who have made this exact project first seen 20 years ago: Dick Soule, founder of Orleans Carpenters, and Dick Dabrowski, whose company, Shaker Workshops, has been at the forefront of bringing quality reproductions and adaptations of Shaker handwork to the public. The Home Shop 517-543-5325 or ShakerOvalBox.com A full line of Shaker oval box supplies, kits and instruction including: ■ #1 copper tacks ($5/oz) ■ "Simple Gifts" music works ($15) ■ music box kit ($35) Lee Valley Tools LTD 800-871-8158 or LeeValley.com ■ #1 copper tacks ($5/oz) ■ box making kits Shaker Workshops 800-840-9121 or ShakerWorkshops.com ■ "Simple Gifts" music works ($15) ■ finished music box ($40) Prices correct at time of publication. popularwoodworking.com ■ 79 |
