Day 042 - The Part I Think I've Been Most Dreading

Post date: May 10, 2013 1:45:27 AM

Last time I made this tissue box, I built each of the side panels before I put a 45 deg angle bevel on the sides (so they would match up and form a box). Adding the angle after the sides were finished was difficult because of the different densities of the woods. The craft plywood needed a lot of work to sand down and the balsa wood needed very little. Being limited in wood working tools, I ended up using a Dremel which quite nearly destroyed one of the sides of the panels. Wood puddy fixed it up, but Dremeling each side was very nerve racking. 

So this time I thought I would do the craft plywood first; before I built the sides. I first tried this setup: a piece of sand paper wrapped around an angle square.

This method was slow and tedious. I then tried a wooden block with the plywood and worked very carefully. It took over an hour with 60 grit paper to get one side done. I stopped for a few days while I thought up alternate plans. Then, I remembered my palm sanders. I knocked out the remaining sides in about 30 minutes. 

Probably obvious solution to most, but you know how things can get when you are too close to them. Also, you don't need an exact 45 degrees, you can go less than 45 degrees (making a sharper angle). The corners will be getting reinforced, so you don't need the edges to match like you do with trim or frames. 

Old Pic

A few days after my last post, I gutted one of the Tardis toys. I am just now getting around to that post as well. Not 100% sure how rigging the tissue box for sound will play out.