Discuss options with cover; edge treatments, dividers

Demonstrate use of miter saw on small wood

MITERED BOX

Requirements:

• Box
• Fine Finish
• Decorative element
• Mortised hinges
• Pull or knob

Show Sample Boxes

Gallery of Artist Boxes

Box Profiles

Cover Types:

• Flush cover
• Recessed cover in dado-with picture
• Recessed cover in Dado+ layers
• Drop-In Cover+ Handle

Techniques: Using a miter saw; cutting a rabbett

• 4"x 4' x 1/2" Aspen or poplar
• 1/4" plywood or strapping, glued up
• Glue
• Stains
• Milk Paint
• Polyurethane
• Brushes
• Hinges
• Latches
• 3/8" feet

Stains- Introduce stain application

Stain wood

Demonstrate mark-up and cutting of sides- mark length, sktch in angles

Review use of miter saw.

Demonstrate use of router to make rabbetts.

• Rip wood to width- 2", 3", 3.5"
• Rout rabbett for bottom cover, 1/4" groove for picture-frame top cover
• Cut sides to length using miter saw
• Optional: Mark angles if multiple-sided
• Cut sides with miter saw , matching opposite sides
• (Rabbet top and bottom for covers)

Assign cleanup jobs

Demonstrate glue-up of box using picture-frame clamp- size joints with diluted glue, then use straight glue.

Demonstrate use of bandsaw- mark line, cut relief cuts, work your way in

Explain progression of grits

Demonstrate gluing of covers

• Clean up joints
• Sand sides
• Tape-up sides
• Sand and plane flat
• Mark up cover stock to fit + extra
• Cut cover stock with bandsaw
• Sand with random orbit sander--80-150-220 grit
• Glue on covers with bar clamps using woodglue- take care that clamps put pressure over sides, not middle

Bandsaw Safety Form

Option: Glue up sides and covers in one operation- helps maintain flatness

Demonstate safe use of router

Demonstrate use of plane.

Demonstrate doweling technique.

Demonstrate use of drill press.

• Trim most excess wood with bandsaw
• Trim cover flush with sanding block or flush trim bit
• demonstrate router safety
• Mark location of cover cut
• Cut box open on table saw( teacher)
  Sand/Plane edges
• Add pull or handle-dowel in place

• Final sanding
• Mortise hinges

Videos: Cutting a Hinge Mortise

• Mortising a Hinge Part 1- Marking and Cutting the Mortise



• Mortising a Hinge Part 2- Marking and drilling the Pilot Holes



• Hinges Part 3- Mortising the Cover



• Hinges Part4- Attaching the Hinges



• Hinges Part 5- Fixing Problems

• Mark holes for feet
• Drill holes for 3/8" feet with Forstner bit, glue in place

• Sand
• Glue lining onto bottom
• Add acrylic base colors
• Print design
• Transfer to box with carbon paper
• Etch design into wood with woodburning tool
• Finish with acrylics or dye-stains; gold leafing with size; add polyurethane gloss(2-3 coats) using buffing pad between coats
• Optional: 1/8" pine lining
• Add paper lining or acrylics or flocking to inside
• Install hinges; adjust
• Add latch or pin