Polygon Box

• We have a 5 sided Box.

• 360 degrees to get around a circle.

360/5 = 72.

2 angles make up one corner.

72/2 = 36.

Set the chop saw for 36 degrees.

Wall Constraints:

Length Constraint: 4"-6"

Width Constraint: 1-1/2" to 2-1/2"

Thickness Constraint: 1/4"

Dado: 1/4" from bottom, 1/4" wide, 1/8" deep.

Calculate what you need an then have Duffey Resaw a board for you.

Plane board to thickness.

Joint 1 edge.  Mark the edge that you did not joint.  You need to refer to it when you are using tools and making marks.

Chop end square.

Layout the length and top and bottom of the dado.  Markings should wrap around wo that we can.  Make sure square is on the jointed side. 

Setup the Fence based on marks.  Make sure jointed edge is against miter gauge.

Setup for other marks and use miter gauge to cut.

Make initial cut at correct angle on table saw.

Mark distance for your edge with the angle down and setup saw so it will cut to correct width.

Setup saw to cut correct angle again.

Again:

Mark distance for your edge with the angle down and setup saw so it will cut to correct width.

Chop boards to length.  Use a stick to hold for smaller pieces.

Hold the top edges and put masking tap across to hold together.

Continue taping together.

Run a light bead of glue on all edges.  Don't forget 1 end.

Roll up and tape tightly.  Use Chisel to clean up inside glue.  Outside glue will be sanded later.

Prepare the board you need by determining how much you will need, jointing, ripping, chopping, and adding the dado.

Set the chop saw and make the first chop with the dado on the inside.

Mark the link needed for your box edge and line the chop saw up with the mark.

Set a stop by clamping a board that will allow you to make multiple cuts at the same length.  Make sure to must the board all the way against the stop.

Safety

When cutting make sure your hand is outside of the semicircle, otherwise use a another board to hold it for you.

Cut your board and stay at the bottom of the cut.  If you come back up it will catch the edge and ruin it.

Notice:

The angle is the wrong way so we need to make a chop just on the end of the board that we have left to get the dado on the inside.  You will have to flip your board from now on for each cut.

Here is the correct cut on the end.

Flip the board and cut to length again

Find a piece of wood that you can push boards up against so that they aren't flush on the top side as you make sure that the corners are even and put a piece of masking tape across the edge.

Here is everything rolled up together.

After Gluing, plane to thickness.

Screw the board down to the sacrificial piece.