I-Box Box

[jsburger]

I decided to make a box with the Incra I-Box jig I recently bought. See the original thread here.

http://www.shopsmith.com/ss_forum/woodw ... 18234.html

I started by resawing hard maple and black walnut to 1/2". I jointed the 6" pieces of stock on the jointer in one side and then one edge so that when I resawed them they would be square with the table and fence. Then the SS Pro Planer and then the Performax 16-32 drum sander.

The Powermatic BS with a 3/4" blade worked fine. The SS BS would have done just as well but the boards were too wide.

Then it was a matter of cutting the parts to size and milling the box joints on the Incra. The fingers need to be sanded flush.

The last picture is a dry fit. The bottom is 1/4" Baltic Birch.

I think the top will be Maple with a Black Walnut handle.

FWIW, this jig works perfectly.

[moggymatt]

Looking good. Gotta love the I Box

[Mike907]

Beautiful work.

Did you calculate a perfect pin width, or trim the sides after cutting the pins?

Mike

[JPG]

Beautiful work.

Did you calculate a perfect pin width, or trim the sides after cutting the pins?

Mike

"Then it was a matter of cutting the parts to size and milling the box joints on the Incra. The fingers need to be sanded flush."

[charlese]

Nice work, John!
Don't have a an I Box yet, but love to see it's use.

Glad you showed the prep work of preparing the wood (squaring) prior to using the jig. Nice work!

Another good piece of work shown was the dado placement for the box bottom.

[jsburger]

Beautiful work.

Did you calculate a perfect pin width, or trim the sides after cutting the pins?

Mike

I trimmed it after the joints were milled. In the other thread I referenced, charlese challenged me to make a box joint 14" long that fit well. I did and kept it. I decided approximately how tall I wanted the box to be and measured on the 14" sample to the nearest full pin and made the stock about 1/16" wider. Once all the joints were milled I jointed off the extra.

Since the Forrest blade set will do both 1/4" and 3/8" joints I need to make a similar sample with 3/8" joints.

[jsburger]

Beautiful work.

Did you calculate a perfect pin width, or trim the sides after cutting the pins?

Mike

"Then it was a matter of cutting the parts to size and milling the box joints on the Incra. The fingers need to be sanded flush."

The picture is just a dry fit. Glue and sand the pins flush today. I will work on the lid while the glue dries.

[jsburger]

Nice work, John!
Don't have a an I Box yet, but love to see it's use.

Glad you showed the prep work of preparing the wood (squaring) prior to using the jig. Nice work!

Another good piece of work shown was the dado placement for the box bottom.

Thanks charlese.

[swampgator]

Really fine work, John. Good on you.

Steve, the old swampgator

[jsburger]

Today I got the box glued up and the pins sanded flush and then the entire box sanded to 320 grit. I used the SS disk sander with 100 grit to get the pins down close. I used the quill feed and fence. Then got them smooth to the sides with 100 grit on my PC air powered random orbit sander. Finally sanded the whole thing with the ROS and a SS G2 ceramic 320 grit disk. That SS G2 paper is really outstanding. It lasts way longer than anything else I have ever used and does not clog.

The lid didn't get done. I was going to use Maple but didn't have a piece big enough. Time to go to my supplier and stock up. I buy rough sawn stock almost exclusively. I usually keep 4/4, 6/4 and a little 8/4 of both Maple and Red Oak in stock all the time but the cupboard is bare. That is OK though because I have another idea for the lid using both Maple and Black Walnut.