Monster Box

Worksheet

Monster Box Worksheet 

Designed on Vcarve.

Cut out on CNC

CNC didn't cut full dept so I cleaned up with the Flush Trim Bit.

Find the Jig

Clamp two directions so that the pieces don't move.

Verify that the bit is going to cut 1/2" deep.

Utilize a file to open the joints up a bit if needed. 

Check Fit.  Should be secure but not too tight.  Should slide together easily.

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.