How to Build a Japanese Woodworking Toolbox for Beginners

I know should I be thinking John this thing is so small what can you possibly fit into it I mean can you even fit all the hand tools that you use to build this thing into this thing let's find out okay so I'm going to cut the dado in this area here I'm going to use the fence of the table saw so the distance from here to here is 1.5 is about 1.5 inches make this cut first I'm going to move the blade 1/8 of inch make the next cut and move the blade over 1/8 of an inch until I get pretty close to the last one and I'm going to custom fit that to make sure that the vertical piece that sits in here is going to fit nice and tight all right so this gives you a sense of what it's going to look like now I accidentally cut these two grooves a little bit too loose or a little bit loosen that like it but it still works this bottom side this groove is nice and tight so I got my bottom cut out here and you can see it is just off by maybe a sixteenth of an inch so I'm going to playing one edge and get it but it fits in between here and nice and tight the length here is pretty good so figuring out the lid size a little bit tricky now I don't know how the traditional Japanese worker did it but I'm going to show you how I do it and it's fairly straightforward I don't do any measurements I'm just going to clamp this thing on this neck gorram think it should be pretty close to work should be and then I'm going to take up a piece that fits inside like this pretty good but it's a bit too long and then I'm going to put it up against this end it's got to fall through here yep that's going to work there's about a little bit under an eighth of an inch of a gap all right so the imagine these two pieces are attached to lid and the lid drops in like this all right and then it gets pushed this way so this side will meet and the wedge here will prevent the lid from coming out so on this side there's a key that fit into this little pyramid or triangular shape that's created here so in essence this is sort of like a dovetail and fits in like so here are all the pieces come out here's the lid the end pieces so this is from recycled piece of board so one face is already being used I'm going to keep this face but clean up the rest of the faces of my plane I added this piece to keep everything nice and square while it is the glue is drying probably should have just made a piece to fill that hole up hey look it's that same piece of scrap wood that's about a quarter of inch thick I'm using a marking gauge to help me locate the horizontal positions for where I need to drill these 1/8 inch holes all the horizontal holes follow Pascal's triangle it is spaced 1 1 2 1 1 3 3 1 etc and the vertical ones are just in groups of 3 except on the side with the drawer there is no it's missing two of the pins looks like somebody listened to me so what a last thing to fix is a store it sits in a little bit further than it should or than I like it to be so I'm going to do is add screws on the back wall here so that when I close it the screw so I hit the other side of the box and it closes flush in about this position if the finished handle looks weak to you I'd have to agree but check out the description for a link to a video where I tested the strength of this handle the way I tested the design of this handle be careful when you're screwing the MDF has a tendency to split between the two phases so to start off mark the center of the wedge piece that this is the side that does not have the lock on it I'm also going to mark the center of this lid piece when I'm gluing I'm trying to keep them to keep these two lines nice and aligned so I'm just going to eyeball that the bottom edge here and this edge are about a quarter into a part and I'm going to use my square to make sure that these two pieces form a nice square shape so it's about a quarter of inch and then one clamp this guy behind it now we have to pick this one off and now I'm ready to believe the bottom these two pieces together so this thing must have shifted when I glued it because there's a little bit of a gap between these two pieces and there's no gap up here alright so I was able to close this gap with a rebate blank so once this piece once this piece is attached to the lid the wedge or the lock piece then come in and slide in like this and you can see this wedges everything together so I'm just going to align this piece and I'm going to draw a line behind it so from this smart line I'm going to move in about 1/16 of an inch I'm just going to eyeball or that is maybe a little bit more so next I'm going to tilt this about another 16 so the distance from this mark to this edge this mark to this Jesus sixteenth from here this mark to this edge is about 1/8 then we'll make another mark here before I blew this piece down decided to put two screws in here and then think that will stop it from moving I have the glue on the other side all right so these two pieces created taper going from Y to narrow and the key piece here fit very far so what I need to do is simply taper this side to fit the angle of this thing which is about 1/8 of inch over a span of eight inches don't get too attached to the key piece as the box is being used that lid is probably going to loosen up and that key probably going to be too loose and you're probably to make a needle I think a project like this really advice to be touched so it's important to knock off all the sharp edges so that when the hand runs over it it's going to feel real good design in proportion are two very apparent phenotypes of any creation and it is impossible for a man to get those two right to get those two perfect but it is fun to try think this side looks a lot better than this I almost forgot to install the feet can even fit all the hand tools that you use to build this thing interesting yes with the room to spare i like to think i use a stanley number four throughout this entire project I put it in there anyways it was still room left

pexels photo 4997809

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