Woodworking class
Pencil box Instructions
Empower
Growth
ALWAYS LABEL ALL YOUR WOOD WITH YOUR NAME AND BL. ___. STORE YOUR PROJECT IN A BAG YOU’RE YOUR NAME ON IT TOO. EXAMPLE: John Doe Block A. JD/A If someone has the same initials as you add your middle name to your initials. This is to prevent lost, mistaken or stolen projects!
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Pencil box Instructions
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Step 1 - Face Side
Make a flat side using a hand plane. Use a ruler on its edge, to see where your high and low spot are. Mark this side with an X when flat. This is called a face side.
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Step 2 - Face Edge
Make a flat edge using the hand plane. Use a square to see if it is 90° to the face side (made in step 1). Mark this side with an X when flat. This is a called a face edge.
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Step 3 - Cutting rough width on the band saw
We now need to make your wood 3 ¼” wide. Mark a pencil line 3 ¼” and at 3 3/8" across the width of the board. Cut your board on the band saw 3 3/8" wide using the fence. Get permission from the teacher before turning on the band saw.
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Step 4 - Hand plane final width
Using the hand plane, make a couple passes on the edge until the width of the board is 3 ¼”.
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Step 5 - Reduce board thickness to 3/8"
Make a second flat side and reduce the thickness of the 3/8”. You are doing this step on the side of your board you have not hand planed yet.
Step 6 - Mark 4 box pieces at 2 3/4"
Mark and cut your board into 4 pieces at 2 ¾” long. When you lay out your pieces leave about 1/16” between pieces for the kerf of the blade. Kerf is defined as the width of material that is removed by a cutting process. You can use the little band with the crosscut box to cut.
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Make sure to label your pieces with numbers like the picture below. This will help you figure out what pieces go together.
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Step 7 - Lay out box cuts
Lay out box cut joints, practice and practice on scrape wood to make sure you make a successfully box joint. When you think you are ready, show the instructor your practice box joint for permission to cut your good ones. Watch Woodworking for beginners 04 video for help with this step.
Step 8 - Cut your Finger (box) Joints
Cut only one side of each Finger (box) Joint. Then compare to the Finger (box) joint that matches it. If you cut it perfect, awesome. If fix your lines so when you cut the other side of the finger joint your 2 pieces will match nicely.
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Step 9 - Sand the inside of your box
Sand all the insides of your pencil box so you can glue it together. YOU MUST SAND FIRST BECAUSE IT WILL BE VERY DIFFICULT TO DO IT AFTER YOUR PROJECT IS GLUE TOGETHER.
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Sand with 80 Grit (Blue)
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Sand with 120 Grit (Red)
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Sand with 180 Grit (Green)
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Sand with 220 Grit (Black)
Step 10 - Glue your box together
Use a strap clamp to glue your pieces together. Remember to put glue on both sides of the finger (box) joints. Wipe off all the wet glue on the inside or your project before leaving it to dry. Use a wet paper towel and a puddy knife to remove the glue.
Step 11 - Fill any gaps in the corner joints with Sanding sealer
Step 12 - Cut the plywood bottom for your box
See Video below.
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Step 13 - Glue the supports for your plywood bottom into the box
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Step 14 - Finish all your sanding up
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Sand with 80 Grit (Blue)
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Sand with 120 Grit (Red)
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Sand with 180 Grit (Green)
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Sand with 220 Grit (Black)
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Take a wet cloth and wipe your project. You are trying to raise the grain so you can sand of the wood grain that has laid down when you were sanding. This will make a smoother finish in the end.
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Sand once more with 220 grit sand paper.
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GET YOUR PROJECT CHECKED BY THE TEACHER BEFORE THE NEXT STEP.
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Put your initials the bottom side of your project to prevent threft.
Step 15 - Apply one coat of Poly-wipe-on finish
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You will need a pair of glove and small cloth out of the teacher office in cupboard 1.
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While wearing gloves and safety glasses, put on a thin layer of finish.
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Please hang your gloves up for reuse tomorrow.
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Please put the cloth in the fireproof garbage can in the finishing room
Step 16 - Sand with 320 grit sandpaper and then apply one more coat of Poly-wipe-on finish​
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Step 17 - Fill in a marking sheet for your project and hand it in for marking.
Pen box Instructions
Pen box Instructions
Step 1 - Face Side
Make a flat side using a hand plane. Use a ruler on its edge, to see where your high and low spot are. Mark this side with an X when flat. This is called a face side.
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Step 2 - Face Edge
Make a flat edge using the hand plane. Use a square to see if it is 90° to the face side (made in step 1). Mark this side with an X when flat. This is a called a face edge.
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Step 3 - Cutting rough width on the band saw
We now need to make your wood 2 ¼” wide. Mark a pencil line 2 ¼” and at 2 3/8" across the width of the board. Cut your board on the band saw 2 3/8" wide using the fence.
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Step 4 - Hand plane final width
Using the hand plane, make a couple passes on the edge until the width of the board is 2 ¼”.
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Step 5 - Reduce board thickness to 3/4" for the pen box.
Make a second flat side and reduce the thickness of the 3/4”. You are doing this step on the side of your board you have not hand planed yet. Use a marking gauge to mark the depth. Marking gauge are in the cupboard closest to the sink.
Step 6 – Make the pen groove – you must practise this on scrape wood first before doing it on your good piece.
The groove will be placed ½” in from the edge you would like to be the front of the pen box. The groove needs to be about ¾” wide. Mark the lines down the whole length of your pieces. The depth of your groove will need to fit ½ the pen into it. Making it so the pen will fit in the groove when both sides are put together. The groove depth on each side will be about ¼ to 3/8” deep.
Step 7 – Cut the top and the bottom of the pen box to length
I would recommend them to be 6” long for streamline pens. However, if you are making this box for a different pen, you will have to adjust accordingly.
Step 8 – Cut 45 degree angle on the back inside edge of the top and bottom of your pen box.
This cut will enable the pen box to open.This guy would normally be done on the small band saw.The table needs to be set at a 45° angle and the fence needs to be used to cut straight.You are only cutting off about half the thickness of your wood at a 45° angle.
Step 9 – Cut the end of the pen box
To size the ends of your pen box, put the top and bottom together and trace the end on to the wood that you are using for the end of your box.This will then need to be cut out on the bandsaw.Please make sure you cut it a little bit larger than the lines you've traced to give yourself space to sand your wood to the correct size.
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This will be cut out of a contrasting type of wood. There is African mahogany that you can use at no cost. If you would like to use a different type of speciality wood there will be a little bit of a charge depending on the type you want.