Simply Beautiful Boxes by Doug Stowe

Author:Doug Stowe
Language: eng
Format: epub
Tags: epub, ebook
Publisher: Penguin Publishing Group
Published: 2000-01-15T00:00:00+00:00

25 Use clear glue to attach the box to the base. Then use masking tape to clamp the parts together as the glue dries.

26 Use copper wire twisted tightly around the reeds to hold them in place before gluing the pulls into the box lids.

MY ROUTER TABLE

My “router tables” are quick and easy — just a router turned upside down, bolted to a piece of ¾″ plywood and clamped to the work-bench. When I'm done with it, I can unclamp it and put it away, saving precious floor space in my crowded shop. I use a “pivot” fence with my router tables, which gives a great deal of accuracy, and is so easily made that I can make them in different configurations as I need them (see Figure 1).The pivot fence is simply a piece of wood with a hole through it for a bolt. The bolt attaches it to the router table, and the other end is secured by a C-clamp.

Make the Inserts

To safely accommodate various router bits, inserts will have to be made to fit the hole in your router table through which the bit emerges. I usually get around to making the inserts sometime after the table has been in use for a while.

First, cut several square inserts on the table saw to the exact same size. Round the corners to a ¼″ radius by standing them together on the router table with a ¼″-radius ball-bearing roundover bit. You can use ¼″ maple, plastic, birch plywood or Lucite. Use a fence to cover most of the cutter and to help guide the pieces squarely into the cutter — never do an operation like this with a router held freehand.

Make the Template

With eight strips of ¼″ plywood, construct a template around the inserts. Overlap the plywood at the corners. This will build a template the exact same size as the inserts (see Figure 2). Glue and nail the pieces to each other while surrounding the inserts.

If you want it to look neat, you can cut the plywood pieces to the exact length needed. Remember to make the template large enough so there is room for clamps on it as well as the router base.

Rout the Table for the Insert

Clamp the template in place on the table, and rout for the inserts to fit. I use a ½″-diameter mortise cleanup bit. Adjust the depth of cut so that the bit protrudes beneath the template equal to the thickness of the inserts. Provided the ¼″-radius cutter is precise, the inserts and recess routed for them should fit perfectly. If they are just a bit tight in the corners, sand them a bit or touch them up with a fine rasp.

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