In this detailed guide, Dave from Twisted Workshop shares his process for creating a beautiful keepsake box using finger joints, also known as box joints. This project is perfect for woodworkers of all skill levels who want to create a functional and stylish box.
Materials and Tools Needed
- 3/4″ Sapele wood
- 1/4″ plywood for the bottom
- Titebond III glue
- General Finishes Arm-R-Seal finish
- Briwax for buffing
Tools:
- Table saw
- Dado stack
- Router with a straight bit
- Sanding block
- Hand plane
- Random orbital sander
- Chop saw
- Clamps
Step 1: Cutting the Boards
Dave begins by marking out all the parts of the box. He cuts the boards to rough dimensions using a table saw sled, then refines them to their final width and height with the table saw fence.
Step 2: Making the Finger Joint Jig
To create the finger joints, Dave makes a quick jig using a miter fence and a scrap piece of wood. He cuts a half-inch thick strip from the scrap wood, which will serve as the guide for the finger joints. He then adjusts the dado stack on his table saw to achieve the desired thickness and height for the cuts.
Step 3: Cutting the Finger Joints
Once the jig is set up, Dave cuts the finger joints on all four sides of the box. He utilizes a quarter-inch plywood piece for the bottom, which will fit into a groove cut around the perimeter of the box. This groove is created at the router table.
Step 4: Preparing for Assembly
After ensuring that all joints fit snugly, Dave sands the inside parts of the box with 150 grit sandpaper to make the assembly process easier.
Step 5: Assembling the Box
Next, Dave applies glue to all the finger joints and positions the plywood bottom before clamping everything together. He emphasizes the importance of checking for squareness during this step.
Step 6: Creating the Lid
Once the glue dries, Dave works on the lid. He flushes up the sides and cuts a small recess around the bottom of the lid to ensure a snug fit against the box. After applying glue, he clamps the lid in place and lets it dry overnight.
Step 7: Sanding and Filling Gaps
After the glue has dried, Dave uses a low-angle block plane and a random orbital sander to smooth out any proud finger joints. He notices some gaps in the joints and shares a technique to fill them using a slurry of wipe-on polyurethane and sawdust.
Step 8: Separating the Lid
To separate the lid from the box, Dave sets up the table saw to cut through half of the finger joints. He carefully adds spacers and tape to ensure everything stays in place while he makes the cuts.
Step 9: Finishing the Box
For finishing, Dave applies three coats of General Finishes Arm-R-Seal, followed by buffing with steel wool and Briwax for a smooth, satin finish. He demonstrates the installation of antique brass hardware, making the box not only functional but also aesthetically pleasing.
Final Thoughts
Dave expresses his satisfaction with the final product, highlighting the beauty of the finger joints and the rich color of the sapele wood.