Steve Ramsey from Woodworking for Mere Mortals presents a fantastic woodworking project that serves as an excellent introduction to the hobby. This guide will walk you through the process of creating a simple box using the rabbet joint method, a technique that provides strong, square corners without much fuss.
Materials and Tools Needed
- 3/4 inch lumber (available at any Home Center)
- Wood glue
- Screws
- Clamps (various sizes)
- Table saw
- Miter gauge
- Strap clamps (recommended)
- Half-inch plywood for the base
- Paint stirring stick with sandpaper for sanding rabbets
Step 1: Cut the Sides and Lid
The first task is to crosscut the four sides of the box to their respective lengths. The last two cuts will be for the lid, which you will set aside for now. Following this, rip all the sides down to the same width.
Step 2: Glue up the Lid
Next, glue up the two pieces that will form the lid. It’s important to shave a little off each edge to ensure a snug fit. When edge-joining boards, apply gentle clamping pressure to avoid buckling.
Step 3: Ensuring a Flat Edge
Check the edge of your glued pieces to ensure they are not curved. If there is any bending, use a couple of cauls (boards with packing tape) to flatten them out. This step is crucial for a neat finish.
Step 4: Cutting the Rabbets
There are several methods for cutting rabbets. For this project, Steve recommends using a regular table saw blade to make multiple passes. Set up a sacrificial fence to protect your actual fence and lower the blade to half the thickness of the board.
Step 5: Making the Cuts
Start making cuts on the ends of the longer pieces to create the rabbets. Ensure the width of the rabbet matches the thickness of the board. This setup is safe since you are not making a through cut.
Step 6: Testing the Fit
After the cuts, test the fit of the pieces to ensure they fit snugly together. Adjust the setup as necessary to achieve a perfect fit.
Step 7: Preparing the Bottom Panel
For the bottom panel, dry fit all side pieces together. If you have a strap clamp, it will make this process easier. Otherwise, regular bar clamps will work as well.
Step 8: Gluing the Box Together
Now, glue together all the sides and the bottom panel at the same time. Ensure to apply glue to both surfaces for a strong bond.
Step 9: Finalizing the Lid
After the glue has dried, check the lid. Cut it down to its final size, making it slightly larger than the box for a nice lip all around. This detail adds to the aesthetics of the box.
Step 10: Sanding the Rabbets
Use a paint stirring stick with sandpaper attached to sand the rabbets for a smooth finish. This simple tool is very effective for this task.
With these steps, you will have successfully built a basic box that serves as a foundation for many other woodworking projects. Steve’s approach simplifies the process and makes it accessible for everyone.