Profiling
Posted: Mon Mar 19, 2012 8:20 pm
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.
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.