Keepsake Box
Introduction
Table of Contents
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Beginning the Jewelry Box.
You will begin with a 40” long, 3” wide, and ½” thick piece of Poplar.
See Mr. Kathrein to receive the piece of Poplar.
Measure this piece. It must be at least 37.5” long to get all 4 pieces needed.
You will be making two long sides 11-3/8” long and two end pieces 7” long.
1.Cut the sides to length.
Watch the video below for instructions on how to use the table saw to cut 4 sides to the exact length required.
Watch the video below.
See me for help cutting these to the correct length.
They need to be perfect or the box won’t be square.
2. Cut a 1/4” slot along the bottom of the 4 side pieces to hold the bottom panel.
Please watch the video below for instructions on how to use the table saw to cut the slots needed to fit the bottom panel.
Please see Mr. Kathrein to remove the blade guard and for help setting up the table saw.
You will do this cut using the table saw or router table (if the router is set up).
If using the table saw, see Mr. K for help. The blade guard will need to be removed.
Label the top of each side piece.
The bottom is the edge with a notch cut in it.
You will need to cut box joints later and knowing the top and bottom will be important.
Watch the Box Joint video to learn what Box Joints are and how to set up and cut them.
This video goes over some important Box Joint information.
3. Label the 4 corners that will be connecting to each other.
You can use 1-4 or A-D to label them.
See the example below.
You will be assembling your project using Box Joints.
DO NOT losen or change any settings on the Router Table with the Box Joint Jig.
Changing settings will mess up your and other student's projects.
Box Joint Sample
4. Cut Box Joints in the Long Side Pieces.
Watch video.
We are using a Rockler Box Joint Jig a the router table.
You can make a Box Joint Jig on your own, they are pretty simple.
DO NOT CUT THE BOX JOINTS YET!!!
You may need to watch the Box Joint video several times to fully understand and remember the process
Bringing your device back to the router table is a good idea for this step.
Cutting without understanding what you are doing will cause major problems that cannot be undone!!!
See Mr. K. or a student who has done this successfully for help if needed.
You may only ask for help if you have watched the video several times and still feel unsure of your success.
Cut ONLY the long sides right now.
The short sides are cut differently from the long sides.
5. Cut Box Joints in the Short Side Pieces.
Watch the video.
The short sides are different than the long sides.
If you cut both pieces the same way they won't interlock and you will have a major problem with your project.
See Mr. K. or a student who has done this successfully for help if needed.
You may only ask for help if you have watched the video several times and still feel unsure of your success.
See Mr. Kathrein for a 1/4” thick piece of plywood for the bottom.
It will need to fit inside your project.
You will need to measure the inside of the box and add ⅜” to each side.
The bottom should be approximately 11” long & 6-½” wide.
If you had to modify your project (cut off and redo box joints, etc.), it will be a different size. Be sure to let Mr. Kathrein know you need a different size than the standard.
Fit your pieces together without glue.
Check to see if everything is square.
This step is shown at the end of video #5.
If the bottom is too big or small See Me and I can cut it to the correct size for your project.
6. Hinge placement.
You won't attach hinges yet, you will be laying out where they go.
Measure 1" from each edge on both sides of 1 of the long side pieces.
(See video for further explanation).
Hinge Length = ¾”
Hinge Width = ⅝”
7. Cutting 2 notches for the hinges.
Watch the video below to see how to set up the table saw to make these cuts.
These are nonthrough cuts.
You will need to see Mr. Kathrein to have the blade guard removed.
The blade should be lowered until it is just a little above the throat plate.
About 1/16"
Watch the next video as well. It's easier to do these 2 steps together.
8. Cut slots in the long side pieces for dividers which will be installed later.
Watch the video below to see how to set up the table saw to make these cuts.
These are nonthrough cuts.
You MAY need to see Mr. Kathrein to have the blade guard removed unless it has already been removed.
The blade should be lowered (or raised) until it is just a little above the throat plate.
About 1/4"
9. Finish sand the side pieces.
Use a handheld vibrating sander to finish sand your project pieces.
Remove the tape from the piece you are working on and then put the tape back on when you finish each piece.
DO NOT sand over the tape like shown in the video.
I had a very difficult time removing the tape after sanding over it.
Assemble the pieces together with the bottom panel inside the frame.
10. Glue everything together.
Watch the video below to see how to glue the pieces together.
You will need a strap clamp and wood glue for this step.
Start working on the top while the glued up box is drying.
11 - Measure Box for Lid
Measure the length and width of your project.
It should be 11-3/8" long and 7" wide, but yours may be different.
12. Cut top trim.
Cut 4 - 1" wide pieces of poplar for the top trim.
These will need to be cut at 45° angles.
See Mr. K. for the lumber needed and help setting up the table saw.
You will need 4 top trim pieces. 2 long pieces that measure 11- 3/8” long & 2 short pieces that measure 7” long.
These measurements assume your Keepsake Box is the correct size.
Measure the length and width of your Keepsake Box.
You may have to adjust these measurements to fit your project.
Use Poplar to make these. Poplar is the greenish wood we have used all 9 weeks.
13. Test fit top pieces together.
Try assembling the trim along the top of your project.
You're just looking to see if the pieces are the correct lenghts.
14 - Label Top Trim Pieces
Watch the video below to see how to label the pieces.
Apply a small piece of tape along the top of each trim piece.
Make a line along 1 edge of each piece of tape.
See the video below, the video can show better than I can describe in words.
15. Cut slots in the top trim to hold the top piece panel.
Cut a 1/2" deep and 5/16" wide groove along the inside edge of each piece of top trim.
Watch the video below to see how to cut the slots in the top trim.
Test fit top pieces together without glue.
Ask Mr. Kathrein for a 1/4" thick Top Piece of plywood.
Do not remove the tape from the trim yet.
Before gluing, put the top together and see how everything fits.
If the top piece is too big or small, see Mr. Kathrein to have one cut to fit your project.
You the tape and the lines you drew on the tape to help with alignment.
They were cut in a specific way and need to be assembled in the same way.
Make sure all the marks on the tape are facing the same direction.
I had all the lines on the tape facing up when I assembled my top.
Add the top panel piece when doing this.
It becomes difficult to hold all 4 trim pieces and the top panel at once.
You may want to ask a classmate for assistance.
If the top panel is too big or small See Me and I can cut it to the correct size for your project.
16. Glue the top pieces together.
See me for the quick-drying glue used in this step.
The quick-drying glue makes it easier to assemble.
Do not over glue or it will take longer to dry, defeating the whole purpose of quick-drying glue.
17. Fill in gaps with wood filler.
See Mr. Kathrein to get some wood putty made.
Fill in any gaps with wood filler.
Don't try to over-apply wood filler in the box joints.
Box Joints are supposed to be decorative, covering them with wood filler makes an attractive wood joint look unattractive.
18. Finish Sand.
After the wood putty dries you will need to sand off any excess wood putty.
You can use a hand-held vibrating sander to do this.
You do not want to use the Belt & Disc sander for this step.
The Belt & Disc sander is too powerful and will change the shape of your project.
19. Measure for Dividers
Measure the width of the divider slots in your project. See video.
20. Dividers
Cut 2 dividers a little long.
You will sand them later to fit snuggly in the divider grooves cut earlier.
21. Test fit dividers.
Test the dividers out to see how long or short they currently are.
22. Sand the dividers to Fit.
Start by using the Belt & Disc Sander to shorten the dividers.
Once they get close to fitting hand sand them with a piece of 80 grit sandpaper.
See video.
23. Apply 1st Coat of Polyurethane (Clear Finish).
Apply a light coat of polyurethane.
Do not soak your project in polyurethane.
Overuse will cause drips.
24 Lightly sand the project.
Lightly sand the project after Polyurethane dries.
Wait (24 Hours).
Apply additional coats of Polyurethane as needed.
Usually, 2-3 coats are required.
Only sand after 1st coat of Polyurethane.
Sanding after the 2nd + coats will apply unnecessary scratches to your finish.
