Making a tiny little wooden box
It's very difficult to mount workpieces shorter than 5 cm in my box joint jig. There isn't enough support behind the work piece, and it's impossible to reach down that far with a clamp.
I made a relief cut in the clamping piece so that it applies pressure near the end.
Here I'm using another piece of wood to make sure my workpieces (four thin ones) are flush with the end.
With the thin kerf blade I use most of the time, meshing a 39-tooth crank gear against the 12-tooth secondary gear (on the 16 TPI threaded rod) produces just the right spacing.
To make the joints mate with the ones I just cut, I need to cut slots where previously I left fingers. So I need to offset the cut positions by half the spacing. I do this by un-meshing the crank gear, turning it half a turn, then re-engaging it. That way, when I now stop with the handle on the right side, everything is offset by half the spacing (which is one tooth width)
There isn't a "stop" on the jig for where to stop the handle. But as long as I stop the gear with the handle within half a tooth of where it needs to be, the cuts will be accurate enough.
Between cuts, the jig needs to be rewound back to home position. That takes about 10-15 seconds of cranking. I thought I'd save the time by not rewinding and making the second cuts moving left to right instead of right to left. But that was a bad idea. The backlash in the threaded rod and nut caused some offset error.
This was just a test piece, but I glued it together to maybe make a box out of later.
Here I'm cutting the workpieces, using a pencil to hold down the stock as I'm cutting it.
I switched to a 6 1/2" blade. This blade is actually for a battery powered circular saw, but has a 5/8" arbour hole, so it fits in this saw. It was the thinnest blade I could find for the saw at The Home Depot tgat fit this saw.
I made a box with that blade before, so I check what spacing I used for that. At just under 35 mm for 10 fingers, I looked up what the closest spacing I could make with it, then retrieved that gear from my collection. Ironically, I wrote on that gear that it's the one to use with the 6 1/2" blade last time I used it!
Love how tiny yet precise these come out!
Except the whole thing is a bit belated. We actually got married last year. When I mentioned to Rachel that I wanted to see how tiny a box I could make, she had the idea of making it so the ring could go into it.
If it wasn't for the ring, I would have made an even smaller box.
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