9.6: Assembly, Sanding, and Finishing
- Page ID
- 67210
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9.6 Assembly, Sanding, and Finishing
The final stage brings the individual components together.
By this point, the major fitting problems should already have been solved.
Final assembly should be controlled rather than experimental.
Learning Outcomes
After completing this section, you should be able to:
- Prepare the tote for final assembly.
- Assemble the box while keeping the bottom free to move.
- Attach the risers and handle using the demonstrated method.
- Sand the completed project through 320 grit.
- Apply the provided Osmo oil finish.
- Inspect the completed tote for fit, function, and craftsmanship.
Sand Before Assembly When It Helps
Some surfaces become difficult to reach after assembly.
Before gluing, consider sanding:
- interior box surfaces;
- the inside faces of the risers;
- areas around joints;
- the bottom panel; and
- portions of the handle that will be difficult to reach later.
Do not sand mating joint surfaces so much that the fit changes.
Prepare for Glue-Up
Before applying adhesive:
- Complete a full dry fit.
- Gather the clamps.
- Confirm the assembly sequence.
- Protect the work surface.
- Make sure all parts are labeled and correctly oriented.
- Have measuring tools nearby.
- Make sure the floating bottom is ready.
Do not begin glue-up until you understand the sequence.
Assemble the Box
Apply adhesive only to the intended corner-joint surfaces.
Do not glue the floating bottom into its grooves.
Assemble the sides and ends around the bottom panel.
Clamp the box as demonstrated.
Check:
- joint closure;
- squareness;
- diagonal measurements;
- flatness; and
- whether the bottom remains properly seated.
Make adjustments while the adhesive is still workable.
Allow the Box to Cure
Do not rush to attach the remaining components.
Allow the box assembly to cure as directed by your instructor and the adhesive manufacturer.
Once cured, remove the clamps and inspect the assembly.
Clean up glue residue carefully.
Attach the Risers
The risers fit into the prepared dados at the ends of the box.
They are attached using the method demonstrated in class.
Make sure they:
- seat fully;
- remain aligned;
- match each other; and
- support the handle correctly.
Attach the Handle
Fit the solid hardwood handle into the riser notches.
The handle is attached with:
- adhesive; and
- screws.
Drill pilot and clearance holes as demonstrated.
The screws reinforce the connection, but accurate joinery and proper fit should establish the position of the handle.
Do not use screws to pull a poorly fitted assembly into place.
Shape the Completed Tote
After assembly, inspect the project as a whole.
The tote does not need to remain visually boxy.
Refine appropriate areas by:
- softening sharp edges;
- blending transitions;
- refining the risers;
- refining the handle;
- removing small glue remnants; and
- correcting minor surface irregularities.
Do not reshape structural joints to the point that they become weak or visibly inconsistent.
Sand Through 320 Grit
Sand the project through:
320 grit
Use a logical grit progression and do not skip large steps.
Pay particular attention to:
- end grain;
- joints;
- inside corners;
- edges;
- the risers;
- the handle; and
- areas where glue may have sealed the surface.
A finish will reveal scratches and glue residue that may be difficult to see on bare wood.
Inspect Before Finishing
Before applying finish:
- remove all sanding dust;
- inspect under good light;
- check the handle for comfort;
- make sure the tote sits flat;
- confirm the bottom can move;
- inspect the joinery;
- and make sure you are satisfied with the shape.
Finish should be the final step, not a way to hide incomplete surface preparation.
Apply the Provided Finish
The tool tote is finished with the a finish provided in class (like Osmo oil).
Your instructor will demonstrate the application procedure.
Follow:
- the instructor demonstration;
- the product directions;
- appropriate drying time; and
- all finishing-safety procedures.
Apply the finish evenly and remove excess material as directed.
Oily Rags and Applicators
Oil-finish materials must be handled and disposed of according to WMT shop procedures.
Do not leave oily rags or applicators piled on a bench or placed casually in a trash container.
Follow your instructor's directions for safe disposal.
Final Inspection
Before calling the tool tote complete, check:
- Are the box joints fully seated?
- Is the box square?
- Does the tote sit flat?
- Does the bottom fit properly and remain free to move?
- Are the risers aligned?
- Is the handle secure and comfortable?
- Are screws properly installed?
- Are all surfaces sanded through 320 grit?
- Is the finish even?
- Are there visible glue marks or sanding scratches?
- Does the tote function as intended?
This project is not only an exercise in making a box with a handle.
It is an exercise in planning, sequencing, fitting, adjusting, and bringing many woodworking processes together into one finished object.
Check Yourself
- Why might some sanding be completed before final assembly?
- Which surfaces receive glue during box assembly?
- Why is the bottom not glued into the grooves?
- Why should screws not be used to force poorly fitted parts together?
- To what grit should the completed tote be sanded?
- What finish is provided for the project?
- Why must oily finishing materials be disposed of properly?
- What should be included in the final project inspection?