Monster Box

Worksheet

Monster Box Worksheet 

Long Edge against the miter, using arced piece to keep pressure down.

Long Edge Against the fence using two push sticks to keep hands out of harms way.

With the blade set to 1/2" tall use this Jig to make your finger joints.

Clamp board against, 1/2" stick.

Clamp far left where it will not run through the blade.

Hold Clamp trigger and miter handle as you run you boards through.

After cutting, check depth to make sure the fingers are fully engaged.  This is a good example.

After the first cut put the slot over the 1/2" stick.

Clamp directly over the 1/2" Stick.

Hold Clamp and Miter Handle as you run your boards through.

Shift over again and run through one more time.

Layout and Center Punch.

Assemble as show and clamp right on the finger joints and once clamp across to make sure they stay tight.

Drill using 17/64" Bit.  (1/64" bigger than 1/4" dowel.)

Make sure to clear chips  as you are drilling.

Assemble 90 degrees with 3-1/4" dowel.  (Longer than needed.  Will sand 

Sand on belt sander.

Safety

Hold the larger side, use light pressure and stay in motion.  

Move hand toward the center as sanding.

Take the dowel out and reassemble horizontally and test your hinge.

Measure up 2" and then put a 1/4" line in on both sides.

Draw a horizontal line @ 7/8", and at 1-3/4".  The 7/8" line is our center line for teeth.  The 1-3/4" line is to make sure our teeth are not too big.  

Cut the Teeth on band saw.

Again:

Measure up 2" and then put a 1/4" line in on both sides.

Trace the teeth by lining up the 1/4" edges.

Cut to a smaller piece on band saw and then utilize a clamp to hold and cut.  

Safety:

This is safer and will give you more control over the project.

Goal:

Flush on the 1/4" portions.  4" overall.

Make slight cuts until the teeth are engaged.

Bad cuts don't matter too much.  Monster don't have clean teeth.

Completed: 

4" long and teeth fit together.