Chest - Pine Trunk.pdf - Projekty - stolarstwo - amok10

Pine Trunk

Rip Boards

Make Spacer Jig

Assemble Jig

Step 1 - Use four 1" x 4" x 8' pine boards

for the box sides and ends (A, B). Select

boards with tight knots and a pleasing grain

pattern. Cut two 32" lengths from each of

the boards. You will have 8 side pieces total.

However, do not cut the 14" lengths for the

box ends from the remainder of the boards

at this time.

Step 2 - Joint one edge of the eight 32" side pieces,

as well as the 2 remaining lengths of boards.

Step 3 - You may ind quite a bit of width

variation between boards. Because of the

interlocking corner construction (inger

joints) of the box carcass, the lumber must

be identical in width. Rip the boards to a

common width on the table saw, but take

of as little as possible, using the narrowest

board as the standard, as shown in

photo A.

Step 4 - Cut two 14" sections from each of

the four remaining lengths. Do not discard

the waste cutofs. ese cutofs will be used

to make a jig for gluing up the sides and

ends in step 5.

16 Weekend Woodcrafts

www.weekendwoodcrafts.com • www.frontporchcollection.com

By Al Krogh

16 Weekend Woodcrafts

www.weekendwoodcrafts.com • www.frontporchcollection.com January/February 2004

Pine Trunk

Material List

T x W x L

A box ends (8) pine

4" x 32" x 14"

B box sides (8) pine

4" x 32" x 32"

C box corner braces (4) pine

4" x 4" x 12"

D end lid frame cleats (2) pine

4" x 8" x 112"

E back lid frame cleat pine

4" x 8" x 29"

Glue and Clamp

F lid frame back pine

4" x 3" x 282"

Step 5 - To make the spacer jig, lay a box

end out on a surface, and insert 3 waste

pieces between every other board, as shown

in photo B. Take a scrap piece of 4" x 4"

x 17" lumber, and screw from the back into

the spacer jig pieces, as shown in photo C.

is jig will ensure the proper amount of

overlap for the inger joints and will keep

the assembly square during the gluing

process.

Step 6 - Apply wood glue (N) to the edges

of the boards, as shown in photo D, taking

care not to apply glue to the surfaces of the

sides and ends that overlap to form the

inger joints. Loosely clamp the assembly

together. Insert the spacer jig in between

G lid frame sides (2) pine

4" x 22" x 15"

H top upright* pine

4" x 52" x 332"

I box bottom plywood

4" x 134" x 314"

J base front and back (2) pine

4" x 32" x 302"

K base ends (2) pine

4" x 32" x 122"

L base corners (4) pine

4" x 4" x 32"

M lid (4) pine

4" x 32" x 282"

Supply List

N wood glue

O liquid hide glue

P panhead face frame screws (50)

#6 x 14"

Q biscuits (2)

R piano hinge

12" x 282"

S paint, stain, and varnish **

*Pattern needed for this project is located in the pattern packet starting on page 35.

**Items are listed in our Buyers Guide on page 78.

Side View

wood screws

Plane Surface

the boards, making sure that everything

is tight, and tighten the clamps, as shown

in photo D inset. Remove the spacer jig

before the glue sets up, and move on to the

next assembly.

Step 7 - After the glue has set up, latten

the surfaces of the sides and ends using a

belt sander or a planer, as shown in photo

E. Assemble the box for a test it, making

sure the box is square and the inger joints

it. Because of the sanding, the interlocking

ingers of the corners may “stand proud” of

the box surface, but that will be taken care

of after the inal assembly. Perform the

inal inish sanding on the interior surfaces

of the box at this time.

132"

144"

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Weekend Woodcrafts 17

Pine Trunk

4" radius

8" 6" 8"

Round Over Edges

Step 8 - Cut the box corner braces (C) to

the dimensions given in the material list.

Round one edge of each length using a

router and a 8" round-over bit, as shown

in photo F. Pre-drill four 8" holes on the

sides that mate with the box sides and

ends, making sure that each one of the

4" radius

28"

38"

Base Front, Back and Ends Front View

Pre-Drill

Fasten Strips

Glue and Assemble

four screws (P), will drive into a diferent

board on the sides and ends, as shown in

photo G.

Step 9 - Fasten the strips onto the end units,

making sure that the edges line up with the

indented portion of the corner and that the

top of the strip is lush with the top of the

box corner, as shown in photo H.

Step 10 - Apply glue to the mating surfaces

and assemble, as shown in photo I. We

used liquid hide glue (O) for this step

because of the extended set-up time. Use

as many clamps as necessary to square the

structure before screwing it together, as

shown in photo I insets. After the glue has

cured, move to another end.

Step 11 - When the box joints are cured,

sand the inger joint extension lush with

the surfaces of the sides and ends if needed.

Use a 8" round-over router bit to round

over the corners and bottom edge of the

box, as shown in photo J.

Sand Finger Joints

Attach Framing Cleats

Insert Biscuits

Step 12 - Cut the end and back lid frame

cleats (D, E) to the dimensions given in

the material list. Install the cleats lush

with the top edge, using glue and screws,

as shown in photos K and K inset. ese

cleats will be used to fasten the lid frame to

the box carcass.

Step 13 - Cut the lid frame back (F) and

lid frame sides (G) to the dimensions given

in the material list. Refer to the lid frame

drawing for the biscuit locations. Cut the

#0 biscuit slots (Q), as shown in photo L.

Glue and clamp, making sure the frame is

square. When the glue joints have cured,

round the outside front corner of the frame

ends, and run a 8" round-over bit along

the outside top edges of the lid frame. en

sand the exposed portions.

Step 14 - Cut the top upright (H) to the

dimensions given in the material list.

Locate the pattern for the top upright in

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Pine Trunk

Exploded View

Cut Top Upright

Rout Top Upright

Pre-Drill Lid Frame

the pattern packet and trace pattern onto

the blank. Cut along pattern lines using a

band saw or a jig saw, as shown in photo M.

Sand the edges smooth. Use a router with

a 8" round-over router bit on both sides

of the curved portions of the upright, as

shown in photo N.

Step 15 - Mount the top upright to the lid

frame by pre-drilling through the frame

piece, as shown in photo O.

Step 16 - Flip piece over and apply glue

to the mating surfaces. Screw through

the bottom of the lid frame into the top

upright, as shown in photo P.

January/February 2004

Weekend Woodcrafts 19

Pine Trunk

332"

234"

324"

Front View

Mount Top Upright

Step 17 - Turn the box carcass upside down

on a lat surface, and slide the frame unit

underneath. It should extend 8" beyond

the front and sides of the box and should

be lush at the back. Mark the position,

remove the frame, and apply glue to the

mating surfaces. Place the frame back into

position, and drive screws (N) through

Attach the Frame

Place Box Bottom

the bottom of the cleats into the frame, as

shown in photo Q.

Step 18 - Cut the box bottom (I) to the

dimensions given in the material list, and

set it in place, as shown in photo R. e

loor should sit against the bottom of the

corner cleats.

Step 19 - Cut the base front, back and end

pieces (J, K) to the dimensions given in the

material list. Refer to the drawing on page

18 for the cut outs and lay out the cutout

portions on each piece, keeping in mind

that the base construction will be the same

as the box; that is, alternating end grain

20 Weekend Woodcrafts

www.weekendwoodcrafts.com • www.frontporchcollection.com January/February 2004

Chest - Pine Trunk.pdf

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