Toy boxes WIP

Aled Dafis · 12 Dec 2009

I've just been commisioned by Santa to make a couple of toy boxes for my two sons. Santa wanted their names on the front as well, I came up with this.

I made a couple of bookshelves for the boys earlier this year out of edge laminated Pine, which comes in 2440 x 650mm boards (8' x 2' ish) and found them to be easy to work with, and gave a nice finish with very little fannying around, so I decided to down the same route again.

Having dimensioned all parts, i proceeded to cut the tails on the Woodrat. Notice how I clamped all four boards together and cut them all at the same time. As these boards are quite heavy, I decided that a little support was needed. Do you think I could patent the "Adjustable, travelling work steady" (TM) :wink:

I then clamped the front/back panels in turn to the ends, in order to mark out the pin details.

I've actually cut most of the pins also, but was far too preoccupied to take photos, I'll take some tomorrow.

Cheers

Aled

rileytoolworks · 13 Dec 2009

Looking good Aled. Nice crisp edges on those dovetails.

Adam

Aled Dafis · 2 Jan 2010

This post maybe a little late, but rest assured the boxes were ready for delivery by the big man.

To take off where I left you a couple of weeks ago, once the tails were cut on the Woodrat, I marked out the pins in the traditional manner and then sawed the pins with my LN Dovetail saw.

The waste was then removed on the Woodrat. I don't bother setting up the rat in it's dovetailing mode, i just nibble away at the waste until there's just a whisker left next to my previous saw cut. This method is pretty quick and gives great results as all baselines are cut accurately, and by using the rat to "climb cut" it gives absolutely no tearout.

The remaining whiskers were pared away with a sharp chisel.

I relieved the inside corners of the tails, as per Allan Peters / Rob Cosman.

Here's what they look like when assembled.

Given the pressure to get the job done in time, I'm afraid that I forgot to take any WIP shots of the rest of the project. Here's what they looked like on christmas morning.

The recess for the names was cut using a laser cut template (boy, it's handy being a teacher) and a router and guide bush. The recess was sanded with one of those "delta" sanders that I hadn't realised how handy they were. The letters were cut on the CNC mill at school and superglued in place. The soft closers came from Sugatsune, and work beautifully.

The boxes will receive a light oak stain and a couple of coats of wax in due course. I didn't manage to get the finish on in time as I had another project on the go at the same time.

These sheds were cut on the laser from MR MDF and painted in the kitchen every night during the week up to christmas after the boys had gone to bed. I used a "tabbed" design so that all panels would (should) fit together easily, but unfortunately I hadn't accounted for the MDF swelling slightly during painting, boy, was that assembly stressful!! and there was absolutely no time to re-make any parts :shock:

Needless to say, I spent christmas afternoon "recovering".

Cheers

Aled

Paul Chapman · 2 Jan 2010

Very nice, Aled. I bet the boys were pleased.

Like the chainsaw 8)

Cheers :wink:

Paul

MikeG. · 2 Jan 2010

Nice work Aled! Pity they won't last 5 minutes with that chainsaw knocking about. You will post the "After" photos, won't you?

Mike

Aled Dafis · 2 Jan 2010

Yes, the chainsaw was one of my favourites also. Sthil have really gone to town on it, it came in full Sthil packaging with the holographic tape, full instruction manual, in excatly the same format as my "proper" manual, it even came with a spare chain and spanner. Needless to say, we've all been cut to bits many times over by now.

The sound effects do get a little waring after a while though!!

Cheers

Aled