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School Box Guild Build

author-gravatar Sean Oct 09, 2016

This is my version of the School Box that's featured in the book  'The Joiner and the Cabinetmaker' (Lost Art Press). If you want to build one of these yourself, check out the guild build that's currently going on. You will have access to the plans and step by step instructions on how to build it. 

My box is made out of quarter sawn white oak and was finished with 1.5 lb blond shellac. The video below shows how I made it.


Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build
Photo of School Box Guild Build

I begin this project by cutting the box parts to size. Since I'm using rough lumber and didn't have boards wide enough, I glued pieces together to get the size needed. To get the sizes for this project, check this image out: http://www.simplecove.com/assets/images/201d6a25-7b92-469a-8aef-750258bc1d28.jpg 

Photo of School Box Guild Build

Next, I laid out the dovetails with my dovetail marker, combination square and pencil. I like to cut the tails first but that's just a personal opinion.

Photo of School Box Guild Build

I set my marking gauge to the thickness of the lumber and scribe a line on all 4 sides of the tail boards. This will indicated the depth for sawing.

Photo of School Box Guild Build

Using my dovetail saw (This is a western style dovetail saw, but you can use a $30 dozuki from Amazon to cut these), I cut the tails, focusing on keeping the saw square to the board. The angle of the cut isn't as important as staying square. You can always cut the pins at that angle, but if it's not square you will run into issues.

Photo of School Box Guild Build

Another shot of how I start the dovetail cut. With this western saw, I like to start on the edge of the board and work back toward my body. Again, just a personal preference for this saw. This old saw has been restored and this method works best for me.

Photo of School Box Guild Build

Once the tails are cut, I remove the waste between the tails with my bow saw. If you're interested in seeing how I made this bow saw, check this out: http://www.simplecove.com/492/sapele-bow-saw/

Photo of School Box Guild Build

And finally, I cut the half pins on the edge of the board.

Photo of School Box Guild Build

I start to chisel away the waste, making sure to remove most of the wood in front of my scribe line (the one I set with my marking gauge) before putting the chisel in the line itself. When I remove the waste, I don't go all the way down, I chisel about half way down on all of the tails, flip the board over and remove the rest of the waste.

Photo of School Box Guild Build

They came out pretty good.

Photo of School Box Guild Build

I have this board laying on top of my hand plan (the plane is laying on it's side) and transfer my tails to my pin board to tell me what I need to saw.

Photo of School Box Guild Build

I use the same dovetail saw to cut the pins.

Photo of School Box Guild Build

Again, I use my bow saw to remove the waste between the pins.

Photo of School Box Guild Build

Just like before, I chisel away the waste half way down, flip the board over and remove the rest.

Photo of School Box Guild Build

This box has a lock on it so this is what i'm installing now. I line the lock up on the front board and use it to mark the area that I need to remove in order to mortise out the waste.

Photo of School Box Guild Build

I use a chisel and small router plane to remove the waste.

Photo of School Box Guild Build

Next up I scribe a line around the inside of the lock for mortising.

Photo of School Box Guild Build

I use my large router plane to mortise the material away. If you don't have a router plane, a small trim router will work just fine. 

Photo of School Box Guild Build

The last piece to mortise out is the outer brass cover of the lock, so once again, I scribe a line with my marking knife.

Photo of School Box Guild Build

And using my small router plane and a chisel I remove the waste.

Photo of School Box Guild Build

And achieved a snug fit!

Photo of School Box Guild Build

To remove the rest of the keyhole material I first drilled a hole (I actually drilled this hole before starting the lock installation) and stuck the blade from my coping saw in there and put the saw back together to remove the waste.

Photo of School Box Guild Build

I pre-finished the inside of the box before gluing it up, but before applying the shellac, I sanded the insides with 120, 180 and 220 grit sandpaper using my orbital sander.

Photo of School Box Guild Build

For the finish (inside and outside of the box) I used a 1.5 pound cut of shellac. That means I mixed 1.5 ounces of shellac flakes to 8 ounces of denatured alcohol. The shellac I used was a blond shellac from BT&C. Also note that I covered up the dovetails as I didn't want the finish to get on them since they are going to get glue on them for the glue up.

Photo of School Box Guild Build

I apply hide glue to the pins and put the box together. 

Photo of School Box Guild Build

The dovetails were a little tight so I needed to use some clamps to pull everything together.

Photo of School Box Guild Build

This box will have a removable tray so I installed some 1/4" boards on the inside for the tray to sit on. Since I pre-finished the inside, I scuff sanded away the shellac and applied some hide glue and clamped them in to place.

Photo of School Box Guild Build

Moving right along, next I cut the bottom panel to width and length over at the table saw. You can reference the cut list in the picture above for the dimensions.

Photo of School Box Guild Build

I apply some hide glue and put the bottom on.

Photo of School Box Guild Build

I put some clamps on the bottom panel to hold it while the glue dried. I also put some 1 1/4" 3d finishing nails on the bottom panel.

Photo of School Box Guild Build

Next up I cut the trim to width over at the table saw.

Photo of School Box Guild Build

This trim has a chamfer that runs along the top, outside edge so I mark that out with my combination square. I have it set to 1/4" and run a line along the top.

Photo of School Box Guild Build

And then I run a line 1/4" on the side.

Photo of School Box Guild Build

Then I use my number 3 hand plane(number 4 plane or block plane would work just fine) to put the 45 degree chamfer on the trim, connecting the two lines.

Photo of School Box Guild Build

Came out pretty good.

Photo of School Box Guild Build

Next up, I tilt my table saw blade and cut the miters in the trim. I will eventually cut these by hand but I need some more jigs for my shooting board.

Photo of School Box Guild Build

With the trim all cut, I glue and nail them in to place.

Photo of School Box Guild Build

Again, I used the 3d finish nails.

Photo of School Box Guild Build

Finally it's time to install the hinges. I mark them out using my marking knife and combination square and use my saw to cut the kerfs.

Photo of School Box Guild Build

Then I switch over to my 1" chisel and knock out a majority of the waste.

Photo of School Box Guild Build

Then using my small router plane I cut the mortises to a consistent depth.

Photo of School Box Guild Build

Fit like a glove.

Photo of School Box Guild Build

I taped the hinges to the top to temporarily test the fit. The blue tape allowed me to move the top around just a tad bit and still remain in place.

Photo of School Box Guild Build

With the lid fitting how I wanted it to, I put the screws in, starting with the back to make sure I can remove the tape and it won't move too much. After I installed the hinges I installed the trim on the top the same way I installed the trim around the bottom.

Photo of School Box Guild Build

I used the same shellac and applied it to the rest of the box. I wiped the shellac on the box but the underside of the lid has the trim which overhangs and creates a ledge. For that, I used a  cheap hake brush which works well with shellac.

Photo of School Box Guild Build

Finally I add the escutcheon plate to the front of the box using brass nails. And with that, the box is complete. Only thing left is for me to make a tray for the inside of the box but I want to see what i'm going to use it for first. Thanks for checking out the photos!

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