After promising the wife to make her a chest to go at the foot of the bed
some months ago, I have been looking at plans and mulling over how to make
one with the tools at hand. My main question concerns the top of the chest.
I suppose everyone makes the top seperately from the bottom, but was
wondering about just making a box and cutting the top off as they do in
making small boxes. As I think about it, I think this would be unsafe on my
smallish DW744, but was wondering if any of you have used a particular
procedure involving a circular saw? My reason for considering doing it this
way is that I think it would be easier for me to get the top to match the
bottom easier. Is this way a ridicoulous idea? Should I try to make the top
and bottom seperate? Thanks for your advice.
It is an excellent idea and makes a perfectly fitting top.
A little trick for cutting a top off the box safely with a table saw.
Before you glue up the box, mark where you want to make the cut line on the
inside and, using hot melt glue, glue 1/2" thick strips across the cut line,
like stitches, three of four on each side.
When you go to cut the top off, make sure that the saw blade is at a height
that won't cut through these strips. The strips will hold the top in place
while you make the cut on the table saw.
It is a simple matter to then cut through the strips, with a small hand saw.
Use hot melt glue as it is easy to remove from the inside of the top and
Just as a suggestion why not make a slight overhang on the top. Like the
one found here perhaps.
Woodworker & CH-47D Pilot
Your circular saw should work. Don't cut all the way through. Leave
maybe 1/8" and cut that by hand. Some kind of jig or fence attached
to the circular saw will keep the blade where it belongs. Sometimes a
small saw is good when working on a big project.
I've seen this done very successfully using a hand saw to cut the top & bottom
apart. If, like me,
your handsaw control leaves a little to be desired, then you can clamp a
straight batten along the
cut line as you go round. Going slowly will at least limit you to small
mistakes (which, after a
bit of "fettling", will be unnoticeable), as opposed to ripping the top off with
a TS/CS, which
could result in a big mistake on your nearly-finished chest, especially if your
power tool setup
isn't big enough for the job.
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