9.2: Preparing the Box Parts

9.2 Preparing the Box Parts

The main box begins with four matching pieces:

• two long sides; and
• two short ends.

These pieces form the frame that will eventually hold the floating bottom panel.

Accuracy matters, but matching parts is often more important than making each part independently match a theoretical number.

Learning Outcomes

After completing this section, you should be able to:

• Select suitable stock for the box.
• Mill the box parts to a consistent thickness and width.
• Produce matching pairs of sides and ends.
• Consider grain and appearance when laying out parts.
• Prepare and fit the corner joinery demonstrated by your instructor.

Select the Stock

Before milling, examine the lumber for:

• warp;
• knots;
• checks;
• usable length;
• grain direction;
• color; and
• figure.

Whenever possible, consider how the boards will look next to one another in the finished tote.

This is a functional project, but thoughtful grain selection still improves the result.

Mill the Parts Together

Prepare the stock using the standard milling sequence.

The box parts typically finish at approximately:

5/8 inch thick

and approximately:

6 inches wide

Mill the parts together whenever practical so they remain consistent.

If one side is 5/8 inch thick and the other is noticeably different, later joinery and assembly become more difficult.

Do Not Make Short Parts Too Early

A finished short end may be approximately 9 inches long, but a board that short may not be suitable for every milling operation.

Mill stock at safe, manageable lengths first.

Crosscut shorter parts after the required surfacing operations have been completed.

Always follow the minimum stock dimensions for the machines being used.

Matching Long Sides

The two long sides should be the same length.

A small difference from the drawing may be less important than a mismatch between the pair.

For example, two sides that are both slightly shorter than the reference dimension can still make a square box.

Two sides of different lengths cannot.

Matching Ends

The same principle applies to the short ends.

Make the two ends:

• the same thickness;
• the same width; and
• the same length.

Matching opposite parts helps the box assemble squarely.

Grain Continuity

If the material allows it, think about cutting the sides and ends from related areas of the same board.

This can allow the grain pattern to visually continue around the tote.

Continuous grain is not required, but it introduces an important furniture-making idea:

part layout affects appearance.

Lay Out the Corner Joinery

After the parts are milled and matched, lay out the corner joints clearly.

Mark:

• reference faces;
• reference edges;
• matching corners; and
• waste areas.

Do not rely on memory once several similar parts are on the bench.

Machine the Joint

Your instructor will demonstrate the corner-joint method used in your section.

Depending on the method, the operation may involve:

• table saw;
• crosscut sled;
• stop blocks;
• band saw;
• router table;
• chisels;
• files; or
• another approved setup.

The important goals are:

• consistency;
• clean shoulders;
• close-fitting mating surfaces; and
• a joint that assembles without excessive force.

Test Before Committing

Use test material when appropriate.

A test piece allows you to:

• verify a machine setup;
• confirm depth or width;
• understand the sequence; and
• make adjustments before cutting a finished project part.

This is especially valuable when several joints depend on the same setup.

Dry-Fit the Box

Before cutting the bottom grooves or applying glue, assemble the four box parts without adhesive.

Check:

• joint fit;
• matching side lengths;
• matching end lengths;
• flatness; and
• squareness.

Measure both diagonals.

If the diagonals are equal, the rectangular assembly is generally square.

Solve fit problems before moving to the next operation.

Check Yourself

1. Why should the box parts be milled together when practical?
2. Why should short finished pieces not necessarily be cut short before milling?
3. Why is matching opposite parts important?
4. What is continuous grain?
5. Why should waste areas be marked before machining joinery?
6. Why should the box be dry-fitted before continuing?