Several of the parts to this toolbox are contoured with a jogged edge, such as the handles and the lower edges of the main carcase boards. I do this cutout using a template and my router table.
Here's a look at the jig I made to do the handles, which have a handhold jogged in about 3/8":
Solid Carbide spiral cutters with a top guide bearing (this one made by C.R. Onsrud) make the work reasonably easy, though I did have a small amount of cutter burn at the jogs:
The burn marks were shallow and easily removed with a bit of sandpaper on a small cylindrical block.
Then I used a Freud 4-flute 1/4" roundover bit to chamfer the outer edge of the handle (sorry for the blurry photo!):
Profiling done, I plane the face of the handles:
Then I rub the handles down with some lubed 400 grit sandpaper.
The result:
A view of the edge of the handle:
A closer look at the jog:
Then I repeated the same process on the lower edges of the main carcase boards. These are jogged in 1/4".
First the long sides:
I use a different spiral carbide bit, this one with dual end bearings, made by Whiteside:
The four carcase board jogged profiles are complete:
I also chose, on the spur of the moment, to add a little detail to the ends of the long side carcase boards. This jog-in gives the lower corner of the box a rounding which makes it more resistant to damaging impacts:
This detail was not shown on the original drawings - you may choose to omit it or do something to your own liking. At a minimum I would suggest rounding/beveling those lower board corners to protect them.
Profiling
- Chris Hall
- Site Admin
- Contact:
- Location: Greenfield, Massachusetts
- Chris Hall
- Site Admin
- Contact:
- Location: Greenfield, Massachusetts
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Re: Profiling
After assembling the box today I decided that the handle wasn't quite right. I couldn't er, handle it. So I took the box apart and removed the handles from the end boards.
Then I set up a core-box bit in the router table, including stops to limit travel on the fence:
A few passes were made to create a hollowed zone for better gripping:
Then the handles were reunited with the end boards:
The grip is much more positive now, so I was glad to have taken the trouble to disassemble so as to look after a niggling problem like this. If you don't have a router table, a gouge would accomplish a similar result - depressions could even be made for all four fingers if so desired.
Then I set up a core-box bit in the router table, including stops to limit travel on the fence:
A few passes were made to create a hollowed zone for better gripping:
Then the handles were reunited with the end boards:
The grip is much more positive now, so I was glad to have taken the trouble to disassemble so as to look after a niggling problem like this. If you don't have a router table, a gouge would accomplish a similar result - depressions could even be made for all four fingers if so desired.
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