I've been looking for wood screws. Not your usual wood screws, but screws MADE of wood. I'd like to use wooden wood screws for a "wood-only" project (a jewelry box for SWMBO). Does anybody know a source for wood screws made of wood?
But for sizes of about 1/4" - 3/8", if you find yourself some boxwood or fruitwood, a good dowel plate or cutter, and an old tap and die set for Whitworth or UNC, then you can cut your own.
The threads needs to be coarse enough. It also helps to use a diestock that has two "square" die halves sliding in a rectangular slot, rather than the usual type with a single round die. The two-part sets can be opened up more easily for the first cuts. Ideally clean them by electrolysis before starting, as dirty dies make dirty screws.
Cut your dowel stock over-length, because the first 1/4" needs to be tapered to get the thread started, and the next 1/4" will be a wobbly thread.
Above this size, look at the Beall tool, or an old thread box.
Hmmm... I think you need to think out-of-the-box (:)); why not just pass on the screws altogether? They are certainly not necessary; there are a zillion ways to build a strong box without screws.
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