The video “INDESTRUCTABLE: I have NEVER seen a box made like this before” is by Stumpy Nubs (James Hamilton). In this video, Stumpy shares the fascinating story behind a box he built seven years ago, showcasing its unique joinery and construction methods that make it a true one-of-a-kind piece.
Stumpy begins by explaining the distinctive feature of the box: the corners are crafted using what he calls “impossible dovetail joints.” These joints are not only visually intriguing but also structurally significant, as they cannot be disassembled without damaging the side panels. This innovative approach to joinery is both mind-bending and captivating, inviting viewers to delve deeper into the craftsmanship involved.
To illustrate the concept, Stumpy contrasts the impossible dovetail joint with a typical dovetail joint. In a standard dovetail, tabs shaped like a dove’s tail fit into angled pins on the opposing side, allowing for a secure assembly that can only be taken apart in one direction. However, the corners of Stumpy’s box feature sloped tabs on both sides, making it impossible to disassemble without breaking the box itself.
The historical context of this joinery technique is intriguing as well. Stumpy recounts how similar methods were used by German immigrants in the construction of log cabins, which have stood the test of time due to their strong joints that resist rot. This connection to historical craftsmanship adds a rich layer to the story of the box.
Stumpy faced significant challenges in adapting this joinery for a box, as building a box differs greatly from assembling logs into a cabin. He had to develop new methods to achieve the desired results. Each dovetail must be cut at a compound angle, meaning that the angles of the face and ends of each tail must match perfectly. This required careful calculations and precise cuts.
To aid in this process, Stumpy created a pattern to lay out his tails, ensuring that the width of the pattern matched the strips that would comprise each side of the box. This meticulous attention to detail is crucial, as the box must be assembled by breaking the sides into strips that fit together seamlessly, much like the logs of a cabin wall.
After preparing the pattern, Stumpy cut the four sides into strips of appropriate widths, marking them to maintain order and grain alignment. He then used his pattern to lay out the dovetails on the outer faces of the strips, ensuring that the cuts would be precise.
To tackle the challenge of cutting compound angles, Stumpy employed a simple jig. He crafted a ramp at the same angle as the sides of the dovetails, which allowed him to cut accurately on the band saw. This clever approach exemplifies his innovative spirit and problem-solving skills.
After cutting the dovetails, Stumpy prepared slots for splines in the edge joints, further enhancing the box’s structural integrity. He meticulously ripped splines from the same material used for the box, ensuring a cohesive design.
The assembly process of the box mirrored that of building a log cabin. Stumpy applied glue only to the dovetails, allowing the bottom panel to float within its slots, accommodating any seasonal swelling or shrinking. This thoughtful design consideration showcases his understanding of wood movement and its implications on joinery.
Throughout the assembly, Stumpy emphasizes the importance of patience and precision, reminding viewers that crafting such a complex piece requires time and care. He also highlights the use of clamps to ensure a tight fit, and if necessary, the clever trick of using glue and sawdust as filler for any gaps.
Stumpy reflects on the rewarding challenge of building this box, noting that it has become a conversation piece, sparking discussions about history, log cabins, and the intricacies of joinery. The craftsmanship involved is not only a testament to his skills but also to the rich heritage of woodworking.
In addition to the box, Stumpy introduces a game-changing tool that has transformed his woodworking experience: the Bow Extender Fence System. This innovative attachment enhances the performance of compact table saws, making them safer and more efficient. Stumpy shares his personal experience with the fence system, detailing how it has improved the accuracy of his cuts and reduced the risk of kickbacks.
Stumpy’s enthusiasm for this upgrade is evident, as he describes how it has made his small job site saw feel more like a larger cabinet saw. The Bow Extender Fence System offers a longer reference surface, greatly facilitating the management of longer rips and sheet goods.
