My brother wants to build some crates for transporting equipment he uses
on construction jobs. His theory is that if he puts each power tool
into a wooden box and then puts the box in the back of his truck it will
suffer less damage than having all the tools stacked on top of each other.
I don't want to discourage him (in winter he is usually shut down
because of cold weather). I could do it for him except we live 1500
miles apart. My prefered approach is with a router. He wants to do it
with a contractors table saw and a daddo to which I say fine. What is
the least he can get away with to accomplish this?
I make my box joints with a contractors saw and a dado.
All you need is a couple of pieces of scrap to make a jig that mounts to the
Look at Fred Bingham's book, "Practical Yacht Joinery" for details.
S/A: Challenge, The Bullet Proof Boat, (Under Construction in the Southland)
If he really wants box joints - I'd do it with the TS and a dado stack. I'd
also use pine instead of plywood which would be much harder on the blade.
If he can live without the boxjoints, consider 3/4 plywood, glue and screws
countersunk enough that you can plug them. I would suspect he's also like
cutouts for handles wouldn't he?
He doesn't have a saw. He was going to look at a used craftsman but it
was already sold. He also does not
seem to want to spend more than a couple hundred dollars on the saw
which is where I think he will run into
trouble unless he finds one used.
Lew Hodgett wrote:
a new $200 table saw isn't worth the trouble. a used , old iron top
table saw probably is.
if his reason to make box joints is decorative, go for it.
if his reason for using box joints is to make a stronger box, consider
that they only make sense in solid boards. plywood boxes will be
stronger overall and allow some details that make them lighter as
well. and decent grade dimensional lumber in wide sizes will add quite
a bit to the cost of this project as well.
I made some boxes to ship tools via air. they needed to serve as
toolboxes for a few months and then serve as shipping boxes for the
return flight. I used the best grade of 1/4" plywood I could get for
the sides and 1/2" ply for the tops and bottoms. I reinforced all of
the corners on the inside with hardwood cove moldings glued and nailed
into place. I figured that the cove would give me the maximum glue
area to weight ratio.
they were strong and light and cheap.
if he doesn't have a tablesaw but does have a handheld circular saw
it could easily enough be done with that and a straight edge. you
didn't say what trade he practises at said job sites, but if it is at
all wood related he either already has one or should go ahead and get
one. if his trade is cable installing or some such he might be happier
with a decent used table saw that stays at home in his garage for
dinking around on weekends. if he goes that route send him a tablesaw
book for his birthday or something. if he is interested enough to want
to make box joints he'll go wild from there....
On Tue, 27 Jan 2004 14:14:49 GMT, william kossack
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