WOODWORKS: BeginneR PROject 2009-2010 JeWelRy BOx

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WOODWORKS: Beginner project 2009-2010Jewelry boxThis felt-lined jewelry box makes a great place to keep your watches and other jewelry. Perfect for beginning woodworkers, this project will giveyou practice in making miter cuts, doing biscuit joinery and applying the felt liner. And when it’s all assembled, you’ll learn more about applyingand using stains and finishes to protect the wood and keep it looking beautiful.– –

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxtools requiredSHOPPING LISTHand Tools– Combination or try square– Block plane– Hand screw clamp– Bar clampsWood Recommendation: White OakAlternate Wood: MahoganyPartQty. Th. x W x LA, B, C11/2" x 8" x 24"D, E, F11/8" x 12" x 12" plywood or hardboardHinges21" x 3/4" brass buttScrews103/8" x #4 roundheadChain17" brassFelt1About 2 sq. ft.Felt pads4Round, self-adhesivePower Tools– Table saw– Jointer– Biscuit joiner– Stationary and portable belt sanders– Random-orbit sanderMiscellaneous– Pencil– Tape measure– Safety glasses– Carpenter’s glue– 120-, 150- and 220-grit sandpaper– Clean, lint-free cloths– Respirator– Rubber tubing (available at a medicalsupply or sporting goods store)– Gloves for finishing– Mineral spirits (for oil-based stainsand finishes)– Water-filled metal container withtight-fitting lid (for oil-based stainsand finishes)– Minwax Wood Finish Stain Brushor other good quality, natural-bristlebrush (for oil-based stainsand finishes)cutting listOverall Dimensions: 3" H x 10-1/4" W x 7-7/8" DPartNameQty. Th. x W x LALid11/2" x 7-7/8" x 10-1/4”BFront, back21/2" x 2-1/2" x 10"CSide21/2" x 2-1/2" x 7-5/8"DBottom11/8" x 7-1/16" x 9-7/16"ELong divider21/8" x 2" x 9"FShort divider21/8" x 2" x 6-5/8"WOOD FINISHING PRODUCTSRecommended FinishPrep:Minwax Pre-Stain Wood ConditionerStain/Finish:Minwax PolyShades Classic Oak (Satin)Alternate FinishPrep:Minwax Pre-Stain Wood ConditionerStain:Minwax Wood Finish Red MahoganyFinish: Minwax Fast-Drying Polyurethane (Satin)– –

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxBefore you begin8. After the glue is dry, sand the outside faces and top edges. Roundover the corners slightly so they aren’t sharp. Now you can proceedto the steps for staining and finishing, (see "staining and finishing"below). Then you’ll complete the box by adding felt lining, the feltcovered dividers, the hinges and the chain in steps 9 through 16.Good craftsmanship begins and ends with good work habits, so makethe following steps part of your routine workshop practice. If you haveany doubts or questions about how to proceed with a project, alwaysdiscuss them with your shop instructor. Carefully and fully review plans and instructions before putting atool to the project lumber. Work sensibly and safely. Wear safety goggles when doing workthat creates flying chips and sawdust; wear the appropriaterespirator whenever making sawdust or working with thinnersor other solvents. At the end of every work session, clean up your shop area and putaway all portable tools.Add Felt Lining9. Cut a piece of felt, with notches, so its center section fits exactlyinside the box. Scissors work better than a knife. Dribble some glueon the box’s bottom. Use a wooden spatula with a tapered end tospread the glue. Make sure the glue is spread thin, or it will soakthrough the felt.10. Place the felt inside the box. Smooth it out on the bottom, makingsure the cut corners line up correctly. Then glue the sides, one at atime. A pointed stick with rounded edges is an invaluable tool forsmoothing the felt into each corner.CUTTING AND ASSEMBLYPROCEDUREMake the Sides and Lid1. You can vary the size of the box as you wish. These plans are for arelatively small box with 1/2" sides and lid (see Fig. 1). The lid (A)can also be glued from two or more pieces. If you’re planing the woodto the final thickness, glue it together first, then take it down to 1/2"with a drum sander.11. Cut the excess felt flush (see Fig. 3). The cutting tool has to beextremely sharp. Use a double-sided razor blade.Make the Dividers12. Cut the dividers (E and F) to width and length. It’s important thattheir lengths are just right to make a snug fit. Check the fit and thencut the notches on the short dividers (F). Make these by placing astop block right next to the blade. Then move the stop block and cutnotches in the long dividers (E) (see Fig. 4).2. The sides (B and C) must be straight and flat in order to makeaccurate miters. Mill this wood to 9/16" thick and 1/4" wider than thefinal width. Let it sit for a few days to give the wood time to acclimateand possibly distort a little. Then joint the faces again and plane,crosscut and rip the pieces to their final dimensions.13. Glue felt on the dividers, wrapping it around the dividers’ topedges. Trim off the excess and cut around each notch. Assemble thedividers and insert them into the box. The assembly should fit tight,but not so tight that you’d have to hammer it in place.3. Cut miters using a crosscut blade in a miter saw or on the table saw.4. Make a simple jig to cut biscuit slots into the miters (see Fig. 2). Tomake slots for #0 biscuits you may need to nail shims to the base ofthe jig in order to place the slot 1/16" below the miter’s inside corner.Experiment with scrap wood before you cut slots in the real pieces.If the biscuit slots are too close to the point of the miter they willpenetrate through to the outside face of the pieces.Add the Lid14. Screw hinges to the box (see Fig. 1). These hinges use delicatebrass screws, so be sure to predrill the holes. Place four pieces ofpaper on top of the box on the hinge side to hold the lid slightly off thetop of the box. This helps prevent the hinges from binding. Place thelid on the box, flush with the back. Mark the screw holes with a felt-tippen or awl. Predrill holes in the lid and attach it to the hinges.5. Saw grooves for the bottom (D). Set the fence 1/8" from the bladeand saw each piece once, then move the fence about 1/64" fartherfrom the blade and make a second pass. The plywood for the bottomshould easily slip into the groove, but test it to make sure.15. Install a chain. On this box, it’s about 6-1/2" long. Locate thescrew on the box’s side 3-3/4" from the inside edge of the back, 1/4"down from the top edge. Stretch the chain tight and lean back the lid afew degrees past vertical to locate the other screw. This screw shouldbe 1-1/4" away from the lid’s edge so the chain falls inside the box asit’s closed.Glue the Box6. Cut the bottom (D) to size. When you figure out the bottom’s exactsize, leave 1/32" of play all the way around, so the miters are sure todraw up tight. Sand the plywood’s edges to make them easier to insertinto the grooves.16. Add self-adhesive round felt feet under each corner of the box.7. Apply glue to all the miters and slots, insert the biscuits, assemblethree sides of the box, slip in the bottom, put the fourth side in placeand clamp the four corners with rubber tubing (available at a medicalsupply or sporting goods store). Tie the knot beforehand to make aloop that stretches taut around the box. One good thing about tubing:glue won’t stick to it.– –

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxStaining and finishing22. Apply the Minwax Wood Finish you’ve chosen using a naturalbristle brush and a clean, lint-free cloth following the directions on thecan. The brush will help you get the stain into the inside corners. Allowthe Wood Finish to set for about 5 to 15 minutes, then wipe off anyexcess. To achieve a deeper color, you may apply a second coat after4–6 hours, repeating the application directions for the first coat. Allowthe stain to dry for 24 hours before applying the protective clear finish.Woodworker’s Tip: Though you may be tempted to cut shortyour sanding, preparation and application time, don’t do it. Thesetasks are very important steps in obtaining a high-quality finish.Remember, it is the finish, just as much as the fit and smoothnessof the parts that will have great bearing on how people judge yourcraftsmanship. To ensure an excellent result, follow the steps listedin this section and also the instructions the finish manufacturerputs on its products.Woodworker’s Tip: When wiping off stain, make certain thatyour last wipe with the cloth goes with the grain of the wood. Thisway, any stain you might miss during wipe-off will be visuallyminimized by the wood grain.FINISHING TIPS Test the stains and finishes you are planning to use on scraps ofwood. On the back of the scrap, mark the stain/finish combinationand the type of wood. Allow all samples to dry thoroughly beforemaking your final finish selection. Save your samples for quickreference on future projects. All stains and finishes must be allowed to dry thoroughly betweencoats. Remember that drying times can vary due to humidity andother climatic conditions. If you have some leftover stain or finish, wipe the can rim so thatstain or finish in the rim won’t dry out and prevent the lid fromforming a tight seal. Brushes used for oil-based finishes must be cleaned with mineralspirits.Applying Fast-Drying Polyurethane23. Apply Minwax Fast-Drying Polyurethane following the directionson the can. Use a good quality, natural-bristle brush. Allow the firstcoat to dry overnight.24. The next day, sand all surfaces lightly with 220-grit or finer sandpaper using with-the-grain strokes. Dust off and wipe all surfaces witha cloth lightly dampened with mineral spirits. Apply a second coat ofpolyurethane and set the piece aside to cure overnight.25. The following day, sand all surfaces lightly with 220-grit sandpaper. Dust off and wipe the piece with a cloth lightly dampened withmineral spirits and apply the third and final coat of polyurethane.17. Finish-sand any remaining rough spots with 220-grit sandpaper.Dust off the piece and wipe it carefully with a clean, lint-free clothlightly dampened with mineral spirits.PRODUCT SAFETYFor your safety and the safety of those you work with, always read thesafety warnings, which manufacturers print on their labels, and followthem to the letter. Typical safety advice and instructions will containinformation such as the following:Recommended Finish18. Before applying Minwax PolyShades, apply Minwax Pre-StainWood Conditioner following the directions on the can.WARNING! Removal of old paint by sanding, scraping or other meansmay generate dust or fumes that contain lead. Exposure to lead dustor fumes may cause brain damage or other adverse health effects,especially in children or pregnant women. Controlling exposure tolead or other hazardous substances requires the use of proper protective equipment, such as properly fitted respirator (NIOSH approved)and proper containment and cleanup. For more information, call theNational Lead Information Center at 1-800-424-LEAD (in U.S.) orcontact your local health authority.19. Apply Minwax PolyShades following the directions on thecan. Use a good quality, natural-bristle brush suitable for use withpolyurethane. Stir the can contents thoroughly before starting andperiodically repeat stirring during your work session. Allow the firstcoat to dry overnight.20. The next day, sand all surfaces lightly with 220-grit sandpaper orvery fine (000) steel wool using with-the-grain strokes. Dust off andwipe all surfaces with a cloth dampened with mineral spirits. Apply asecond coat of PolyShades and set the rack aside to cure overnight.To achieve a deeper color, you may apply a third coat after 4–6 hours,repeating the application directions. Allow the jewelry box to cure forseveral days before using it.When using oil-based wood finishing products:CAUTIONS: CONTAINS ALIPHATIC HYDROCARBONS.Contents are COMBUSTIBLE. Keep away from heat and openflame. VAPOR HARMFUL. Use Only With Adequate Ventilation. Toavoid overexposure, open windows and doors or use other means toensure fresh air entry during application and drying. If you experience eye watering, headaches, or dizziness, increase fresh air, or wearrespiratory protection (NIOSH approved), or leave the area. Avoidcontact with eyes and skin. Wash hands after using. Keep containerclosed when not in use. Do not transfer contents to other containersfor storage.Woodworker’s Tip: If you achieve the desired color on the firstor second coats of PolyShades, apply a clear coat of Minwax Fast-Drying Polyurethane or Minwax Wipe-On Poly foradded protection.Alternate Finish21. Before applying Minwax Wood Finish, apply Minwax Pre-Stain Wood Conditioner following the directions on the can.– –

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxFIRST AID: In case of eye contact, flush thoroughly with largeamounts of water for 15 minutes and get medical attention. Forskin contact, wash thoroughly with soap and water. In case ofrespiratory difficulty, provide fresh air and call physician. Ifswallowed, call Poison Control Center, hospital emergency room,or physician immediately.NOTICE: Reports have associated repeated and prolonged occupational exposure to solvents with permanent brain and nervous systemdamage. Intentional misuse by deliberately concentrating and inhalingcontents may be harmful or fatal.WARNING: This product contains a chemical known to the Stateof California to cause cancer and birth defects or other reproductiveharm. DO NOT TAKE INTERNALLY. KEEP OUT OF REACHOF CHILDREN.WARNING: Contains Alkyl propanols, ethylene glycol, n-methyl pyrrolidone. VAPOR HARMFUL. Use only with adequate ventilation. Toavoid overexposure, open windows and doors or use other means toensure fresh air entry during application and drying. If you experience eye watering, headaches, or dizziness, increase fresh air, or wearrespiratory protection (NIOSH approved), or leave the area. Avoidcontact with eyes and skin. Wash hands after using. Keep containerclosed when not in use. Do not transfer contents to other containersfor storage.DELAYED EFFECTS FROM LONG-TERM OVEREXPOSURE.Contains solvents which can cause permanent brain and nervoussystem damage. Intentional misuse by deliberately concentrating andinhaling contents may be harmful or fatal.WARNING: This product contains a chemical known to the Stateof California to cause cancer and birth defects or other reproductiveharm. KEEP OUT OF REACH OF CHILDREN.SAFE DISPOSAL OF RAGS AND WASTE.DANGER: Rags, steel wool, other waste soaked with this product, andsanding residue may spontaneously catch fire if improperly discarded.Immediately place rags, steel wool, other waste soaked with thisproduct, and sanding residue in a sealed, water-filled metal container.Dispose of in accordance with local fire regulations.This project originally appeared in American Woodworkermagazine, #133, January 2008, page 74.– –

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxFIG 1.EFAFE31" -Long x 3/4" -Wide HingeCB1/8" -Wide, 1/4" -Deep SlotBD#FF or #0 Biscuit1/8"F1"1/8" x #4 Roundhead Screw/8"E1"21/4"– –C

CONTINUED - WOODWORKS: beginner project 2009-2010 Jewelry boxFIG 2.FIG 3.Trim offexcess felt45 BiscuitSlotFIG 4.F21/4"StopBlockE– –

jeWelRy BOx This felt-lined jewelry box makes a great place to keep your watches and other jewelry. Perfect for beginning woodworkers, this project will give you practice in making miter cuts, doing biscuit joinery and applying the felt liner. And when it’s all assembled, you’ll learn more about applying

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