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How not to make a Japanese style toolbox

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Stilldrillin:
Mornin Ross!

Thanks for another entertaining episode.  :clap: :clap:

Did you enjoy last night's steak n wine? (See..... I have been taking notice).  :thumbup:

I've learned a lot from your recent posts. But, I still prefer my angle grinder for finishing off/ tidying timberwork.
Got a couple of oversize fence panels. (Or is it undersize between posts)? To fit, this afternoon........  :(

David D

SwarfnStuff:
What an entertaining and dare I say informative piece of writing. So a lot of the information was how NOT to do, who cares? Good to learn from other's miscalculations, cheaper too,  :) Still a great read and project plus I thoroughly enjoyed the time it took to read. Keep at it.

John B

Pete W.:
Hi there, Ross,

Looks like you've forgot the 'andles,   :D   :D   :D 

And the fings wot 'old the candles.   :lol:   :lol:   :lol: 

Seriously though, well done.   :clap:   :clap:   :clap:  I particularly admire the way you manage without a 'proper' bench, or even a Workmate.

RossJarvis:
Thank you very much for the kind comments Pete, John and David :thumbup:.  It's great to hear such positive stuff and that you're enjoying the progress.  I would like to hope that my own blunderings will encourage anyone with limited resources and experience "to have a go".  As John said, they may even learn from my mistakes :palm:!

David, Last night actually became my second Friday speciality, Salmon in Cream, with Cider Accompaniment.  This is SWMBO's preferred option to the masculine slab of meat.  Thanks for remembering, there will be a test at the end :coffee:.  Good luck with the fence, surely there's nothing that an angle-grinder or Birmingham Screwdriver can't fix.

And now, Drumm-dee-diddle-de-drum.

Ladies, Gentlemen and Accountants, please get ready to take your seats for todays thrilling instalment of Ross-san's series in making shavings and sawdust

Nextly I was going to make the end wotsits that are used as handles for carrying the box (for' kandles Pete?).  All I needed was to make some bits of wood to fit in the recesses at the end of the box, with some spacers and job done.  Can’t be difficult can it?  I was going to cut an off-cut of board in half for this and thought that instead of ripping it, I could use the Japanese technique for cutting thin boards.  If dividing the board along the grain, they use something very like a marking gauge with a knife in it.  They slit down one side then slit the other and snap it.  So I tried slicing/knifing both sides of the board;



…and then leant on it to simply snap along the line.  Lean, LEAN, LEEEAAAANN, nope, no breaking.  So I had to b****y well rip it.  Not noticing any great improvement from the boots yet;



Plane the edges neat and square;



Trim the edges to make the hand holds nice and smooth;



put some spacers in the end of the box;



and all I need to do is pop the handles in, simples;



B******s, another miscockulation.  I’m thinking I measured the gap at the end with two bits of thin board and am trying to fill the gap with two bits of thick board.  So, bang a couple of nails in the “workbench”, jam the boards up to them, shhhh, shhh, shhh, with the No 5 ½  bam, bam, bam and Hey Presto (My Granddad was called Morrison, wonder if it's any relation);



Two nice flush end wotsits, so now one finished outer box (sans rope handles and internals);



Next task is plane the edges of the bits which will make the sides of the tray;



Here you may notice my planing arrangement on my “high-tech workbench”; a few nails to stop movement and hoping that it is upright.  Then I checked to see if the tray will fit in above the plane and leave 15mm clearance for the lid;



As I’ve done so little, I thought I’d show you my nuts!;



The apprentice says he could do with a couple, what with that little operation he had and all!  That’s 2 ½ kilos of wild hazelnuts (Cobnuts to those of you from Kent), picked up over three days going for a walk with the apprentice.  Should save me a couple of quid come Christmas.

Then I got distracted, due to not want to face carrying on planing so I nailed a couple of off-cuts across the bottom for "feet".





That should keep it away from the crud and wet on the “workshop” floor.  Then I had a look at the last bit of board, that’s going to be the bottom of the chisel tray;



Hmmm, I believe that’s called “cupping”, just remember that if you’re thinking of buying pine shelving from B&Q!  This means I’ll have to nail it to the bottom of the side and ends of the tray.  This poses a problem, as the tray bits are just about the right size to fit under the lid and I had intended the base to be nailed “inside” them.  So for no particular reason (apart from not wanting to cut or plane the side/end bits any more) I thought I’d plane a rebate for the base to fit into.  So I nailed a bit of batten along the edge of the “side bits”;



and had a go with the handy No 311;



However I did notice that the rebate was not particularly square across the bottom and wondered if it was due to the blade(iron) not coming out of the slot square;



I re-sharpened the iron twice, but it was still on the p**s (Positional Instability Sloping Situation) and I think it might be because the bed for the iron is actually machined with the Positional Instability problem.  I also noticed that I was not holding the plane particularly square either, so who knows, so I gave up and came in.

TTFN

RossJarvis:
Hmmm, Hrrmmmph.  I can truly say it’s been one of those days of ups and downs, I think the downs won though.

I was going to finish the rebates for the sides of the chisel tray.  Remembering there was a “Positional” issue with the shoulder plane iron, I thought I’d see if I could re-sharpen it and be third time lucky.  First of all I checked if my water-stones were flat.  Nope, so I used the high-tech flattening system. One; draw pencil lines across the stone;



…two; prepare flattening station, here I’m pouring water on the concrete flag-stone in the “workshop”;



….three; rub it up and down and round and round, till you remove the pencil marks;



…check with a straight edge in all directions, if flat, sharpen plane iron;



General improvement and it’s now slightly cock-eyed to the other side.  Anyway, it worked, however it takes a long time and many cups of tea to make this many rebates;



..it was actually sharp enough to go through a knot with no real problems;



Nextly I noticed the lid to the tool-box had wedged itself shut, The wood’ s been moving a fair bit and I think it’s sucked up a fair bit of humidity  (rain?) from the air.  Having gently removed the lid with a block of wood and a framing hammer, I bevelled the edges which seemed to resolve the problem;



You might see that not only has the wood got fatter, it also cupped despite the batten across it.  Following this, I ripped and trimmed some more board to make the base of the tray,cut the sides to length, glued and pinned them on and checked the ends for fit.  These needed side “rebates” so out with Mr 311 again;



shhhmm, shhhmm, shhhm, Pare with a chisel;



bash bang ‘ouch’ and;



Woopsie, that’s a pin which went 90 degrees round a corner and out again;




…and there we go, nearly there.  I was feeling tired, the light was about to fade so I thought I’d pack away, then;



…that’s what happens when you try to stick your water-stones away, on top of the fridge-freezer, without turning the light on in the larder.  B****r, B******s, ****!!!.  That’s a brand new stone, ordered from Japan, that I only got three weeks ago. T**s, B*****y and B******s.  I think I’m going to have to use that for sharpening the nail scissors from now on, S**t.

TTFN.

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