Download Box Builder's Handbook PDF

TitleBox Builder's Handbook
Tags Tools Equipment Industrial Processes Woodworking
File Size3.1 MB
Total Pages17
Table of Contents
                            Cover
Table of Contents
18 Game Box
                        
Document Text Contents
Page 1

X3299eanart.eps


WOODWORKING

Box Builder’s Handbook
ESSENTIAL TECHNIQUES WITH 20 STEP-BY-STEP PROJECTS | A.J. HAMLER

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781440 3119019

52499

ISBN-10: 1-4403-1190-0
ISBN-13: 978-1-4403-1190-1

US $24.99
(CAN $25.99)

Our daily lives are full of boxes — some purely functional,

others purely decorative, but most provide both beauty and

a worthwhile purpose. There are many ways to make boxes;

square, round, long, tall, turned

or bandsawn. In the Box Builder’s

Handbook author A.J. Hamler presents

some of the projects as introductions to

specifi c box styles. Others are stand-

alone projects, but most are an example

of a box type, and as part of the

project he offers tips and

suggestions on how to use

the project as a springboard to make additional boxes of this

type. Follow the step-by-step instructions and diagrams to

build the box of your choice, or build them all and learn a new

skill with each new project. And as a bonus, every project

in this book will make a great handmade

gift for someone special.

Cover_X3299.indd 1Cover_X3299.indd 1 8/4/11 9:13:46 AM8/4/11 9:13:46 AM

Page 2

POP WOOD BOOKS/BLACK


INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . 6

ITTY BITTY BOX. . . . . . . . . . . . . . . . . . . . . . . 10

WINE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

POST OFFICE BOX . . . . . . . . . . . . . . . . . . . . 22

WATCH BOX. . . . . . . . . . . . . . . . . . . . . . . . . . 30

TOTE BOX DUO. . . . . . . . . . . . . . . . . . . . . . . 36

HEART BOX . . . . . . . . . . . . . . . . . . . . . . . . . . 42

POTPOURRI BOX . . . . . . . . . . . . . . . . . . . . . 48

LIDDED LATHE BOX . . . . . . . . . . . . . . . . . . . 54

KIM’S CHRISTMAS BOX . . . . . . . . . . . . . . . . 60

BEAD BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

SPOOL CABINET . . . . . . . . . . . . . . . . . . . . . . 74

SHAKER OVAL BOX. . . . . . . . . . . . . . . . . . . . 84

BAND SAW BOX . . . . . . . . . . . . . . . . . . . . . . 96

PENCIL BOX . . . . . . . . . . . . . . . . . . . . . . . . 104

KESTREL BIRD BOX . . . . . . . . . . . . . . . . . . 114

BUSINESS CARD HOLDER . . . . . . . . . . . . . 120

MAILBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

GAME BOX. . . . . . . . . . . . . . . . . . . . . . . . . . 136

VERTICAL JEWELRY BOX. . . . . . . . . . . . . . 150

CHILD’S BOX . . . . . . . . . . . . . . . . . . . . . . . . 164

TABLE OF CONTENTS

01

02

03

04

05

06

07

08

09

10

11

12

13

14

15

16

17

18

19

20

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Page 8

6 7

8

To make the grain on all four corners continuous, we’ll
cut one side “A” and one end “B” from one board, and the
other side “A” and end “B” from the other. Each board,
then, should first be cut to 145⁄8" in length (the combined
length of a 9" side and a 51⁄2" end, plus 1⁄8" for the saw
blade’s kerf between the two) on the table saw as in Fig. 6.
Now, cut a side and an end from each board, and line them
up end-to-end A-B-A-B with the continuous faces up, and
you’ll see that the grain flows smoothly from one piece to
the next. Marks these clearly A-B-A-B, and remember that
these faces (which were in the center of the slab before

9

you cut) will now become the outside faces of the box. (Fig.
7) To keep the A-B order straight, you might also want to
number the sides 1 through 4.

Cut a 1⁄8" groove for the plywood bottom 3⁄16" deep on
the bottom-inside edge of all the side and end pieces, plac-
ing the groove 1⁄8" from the bottom edge. (Fig. 8) This
would also be a good time to cut the plywood bottom to the
dimensions shown in the cut list.

Set your table saw to 45° and cut corner miters on the
ends of each piece as in Fig. 9. Take your time, and cut off
only enough to make the miters.

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Page 9

10

11

12

We’ll assemble the box the same
way we’ve done the other miter-
corner boxes in earlier projects by
applying packing tape to the outside
corners, then laying the four con-
nected pieces inside-up to apply the
glue. (Fig. 10) In this photo, you can
easily see the continuous grain run-
ning through the miter joints. Now,
insert the plywood bottom into one of
the grooves, and just fold the box up
around the bottom as in Fig. 11. You
can use more packing tape to keep the
box closed, or use a set of band clamps
as I’m doing in Fig. 12. I prefer band
clamps when making mitered boxes,
as there’s no danger of one of the
pieces of tape letting loose. With the
box clamped up, remove any glue
squeeze-out with a damp rag, and
allow the clamped assembly to dry.

Meanwhile, let’s move on to the
lid. I’ve made the lid out of the same
cherry used for the box, but I’ve
added a walnut accent strip down the
lid that will match the corner splines
we’ll add to the box later. Make the lid
by gluing a 1" strip of walnut between
two pieces of cherry, and clamp up till
dry (Fig. 13). If you’re wondering why

142

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Page 16

30

31 32

149

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Page 17

X3299eanart.eps


WOODWORKING

Box Builder’s Handbook
ESSENTIAL TECHNIQUES WITH 20 STEP-BY-STEP PROJECTS | A.J. HAMLER

H
A

M
L
E

R
B

o
x

B
u

ild
e
r’s H

a
n

d
b

o
o

k
T

E
C

H
N

IQ
U

E
S

+
2

0
P

R
O

J
E

C
T

S

POPULAR
WOOD

WORKING
BOOKS

Fn
L1 0

4 01
20

01 J
UYr

VyB
QdW

Jsa
WN

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lvbn

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35313 652310 8

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X3299

Fn
L1 0

4 01
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01 J
UYr

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Jsa
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MsI
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ExB

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04 T
i0xM

w05
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xND
Qw

MzE
xOT

AxA
A==



781440 3119019

52499

ISBN-10: 1-4403-1190-0
ISBN-13: 978-1-4403-1190-1

US $24.99
(CAN $25.99)

Our daily lives are full of boxes — some purely functional,

others purely decorative, but most provide both beauty and

a worthwhile purpose. There are many ways to make boxes;

square, round, long, tall, turned

or bandsawn. In the Box Builder’s

Handbook author A.J. Hamler presents

some of the projects as introductions to

specifi c box styles. Others are stand-

alone projects, but most are an example

of a box type, and as part of the

project he offers tips and

suggestions on how to use

the project as a springboard to make additional boxes of this

type. Follow the step-by-step instructions and diagrams to

build the box of your choice, or build them all and learn a new

skill with each new project. And as a bonus, every project

in this book will make a great handmade

gift for someone special.

Cover_X3299.indd 1Cover_X3299.indd 1 8/4/11 9:13:46 AM8/4/11 9:13:46 AM

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