TOOBOX METHOD
step one to five
step 11
step 13
- measure up the piece of wood
- measure a lines in each corner 60 mm long
- measure another line 5 mm away from the other line
- measure down from the top 120 mm then draw a line across
- measure two lines in the middle with a 10 mm gap
- cut the four corners off at the first line with a tenon saw
- plane down to just above the second line with a jack plane
- sand the corners with the disc sander to the line so it is flat
- measure down 15 mm from the top and put a mark do this on both side
- hammer a little hole into the mark with a nail punch
- drill right through the piece of wood wear the marking is with the drill press make sure you drill the hole on both side (the piece of dowel will go through the holes and connect them)
- cut a 220 mm piece of dowel for the handle
- cut the piece of wood which has the measurements from step 5 in the middle of the two line with the band saw
- sand down each side of the wood you cut with the disc sander (these two bits will be the sides)
- get a new piece of wood and measure 15 mm down and then draw a line across the piece of wood
- then on either side use a marking gauge to mark a 7 mm line
- cut the line that is on top of the wood stopping at the 7 mm line.
- for step 18 you will need a helping block which is just a scrap piece of wood which you clamp on top of your marked wood so your cut is straight
- use a chisel and a mallet hammer to chip away the rest of the wood going up to the bit you've cut
- fix up your chiseling with a hand router plane
- use a hand router to clean the edges up
- rule a 5 mm lime next to where you have chiseled it on both sides
- then cut half way through the piece of wood
- then chisel it so it is level and flat