Glueup

Since I did a successful dry-run, the glueup presented no surprises. I added a dab of glue in the center of the sides to secure the bottom. I made the bottom slightly undersized across the grain to allow for wood movement. This method ensures that the bottom stays centered; any movement happens to each side.

After putting the box together, I clamped it up using pieces of scraps to protect the surface of the wood.

Securing a knot

There was a knot in the bottom piece, with a crack – and I decided to make sure it won’t be a problem in the future. I mixed some 5 minute epoxy, added a drop of epoxy pigment and worked the epoxy into the crack using a splinter of wood. A small piece of tape ensured that the epoxy would stay in place when I flipped the box over. I then applied epoxy to the underside of the box. When the epoxy had cured to a “hard rubber”, I used a chisel to remove the excess. Fully cured epoxy is HARD – this method is way easier. The only thing to remember is that you can accidentally remove epoxy from the crack if you do this wrong, because the epoxy is somewhat flexible. One can remove the bulk of the excess, and then leave it to cure fully before sanding and/or scraping the excess off.

Here’s the successful repair – I think black epoxy looks better than trying to match the color of the wood:

By the way – look at the ray flecs! This feature of quarter sawn oak is So pleasing to the eye, I think!

After the glue had cured fully, I cleaned up the box using my smoothing plane. Notice the relief line around the perimeter of the bottom – a nice detail that won’t be seen…

Oh, well. I know it is there. And now you do, too.

The bottom is almost flush with the sides, just a hair lower. I just think this looks way better than an “inserted” panel. That being said – this was an unnecessary detail since it won’t be seen. The sane thing to do here would be to just plane a wide chamfer around the edge, just to the bottom into the groove in the sides. No need to make a beautiful, flat bottom like this. I did it because I wanted to practice the techniques involved – this would Look great on a door or a show panel.

On the next page we’ll fit the chisel holders.