Rob Patrick Project 1: Building with hand tools

The purpose of this blog post is to document Project No. 1 by (a.) describing the fabrication process, (b.) illustrating how the end result was achieved through thoughtful design, and (c.) discussing reflections on the project.

Design and Planning

The old adage "measure twice, cut once" could be modified to "measure twice, then measure again..." for anyone not adept at woodworking. The assignment: model a tool tote using Fusion 360, then build it in the MakerSpace using wood and hand tools. Fortunately, we were given some latitude to design and build a tote or container more useful for our personal living/work space.

In seeking ideas for what to build, my daughter gladly volunteered her request for an art supplies box to fit in her bunk bed cubby. Upon further investigation of Amazon and Home Depot websites, we quickly found a design concept of her liking (Figure 1). The next step was to measure the actual cubby and consider the clear space dimensions needed to comfortably place the container in and out of the cubby without difficulty, while at the same time maximizing the container space. One last check was to verify that the plywood allotment from class would be sufficient for the desired box dimensions. From the onset, I decided I wanted the end product to perform in both form and function, especially since this would be for my daughter's bedroom.

Now that I had a design concept, the next step was to produce a CAD model and scaled fabrication drawing using Fusion 360. Having had zero experience with this software, the video tutorial was instrumental in my progress. Due to my basic CAD competency, I found that for this design the overall dimensions would be sufficient for a drawing, but that I would need to do more "trigger" work during fabrication, or call "audibles", to use a football analogy. I was able to render and produce overall dimension accuracy (Figure 2), which I then translated into a "cut list" for major pieces (Figure 3). These "rough" dimensions were useful in laying out the cutting lines on the plywood (Figure 4). Handling an eight foot board would be challenging in the shop, so it was helpful to first cut it down into more manageable pieces.

Before the design could be finalized, I needed to understand what constraints I would be facing. I was confident I could fabricate anything with the most basic tools and materials, however, I knew I would need more than a handsaw and a bucket of nails to meet the design objective. What tools would be available in the MakerSpace? What surplus materials could I find? What were the fastener options -- glue, nails, screws? How could I utilize power tools to optimize efficiency and precision? What competency with those tools would be required of me? How much time would I need? I found answers in the MakerSpace...a band saw, a pneumatic staple gun, some wood glue and an orbital sander...now, get to work!

Execution

A rectangular, open top box can be deconstructed into multiples of similar pieces -- two sides, two ends, and the base. I carefully setup the bandsaw for each sized piece, utilizing the fence feature, and made multiple cuts with the utmost precision (Figure 5). After each side of the box was cut, I then had to decide how much spacing would be desirable between the "slats" making up the sides, as shown in the concept picture (Figure 1). Then, subtracting the spaces out of the overall height dimension, I was able to determine the slat heights. Again, using the bandsaw I cut the larger pieces into smaller slats.

The two end top slats would need to have handholds, so using a round plastic lid for a radius template, I laid out the cut lines for the handles (Figure 6). Laying these pieces side by side and centering the lid on the joint, I was able to make symmetrical handles. Due to the curved cuts, I elected to use a jigsaw to cut the handles.

The final piece to figure out was the corner riser support. There would need to be four of these, and the shape could be rectangular or triangular. This piece would support the slats and connect them to the base, but more importantly, they would transfer the load of the contents to the handle. Another consideration was the size of the piece, as both a structural component and an aesthetic feature. Using a triangular shape created a chamfer to the interior of the container, which I preferred for both form and function. The challenge was then to create this piece from plywood or stock materials. Fortunately, I found a clean 2x4 section in the stock supply. Both the chop saw and the band saw can cut a 45 degree angle, but the bandsaw was a safer and more precise option. I was able to "rip" the 2x4 lengthwise at a 45 degree angle using the bandsaw, then trim this piece into four smaller pieces of equal length.

Finally, now that all the pieces had been cut, it was time to do a test fit. Using no glue or fasteners, I built up all the pieces in place, similar to playing the game known as Jenga. Next, in order to soften the edges of the pieces, I used the corner router tool on every edge of every piece. I then chose to use glue and a pneumatic staple gun as the means of connecting all the pieces. Clamping the freshly glued pieces enabled me to place the staples appropriately and get a solid connection (Figure 7). By applying the correct amount of air pressure to the staple gun, I was able to countersink the staples so that I could later cover them with wood putty if desired, virtually causing them to disappear from view (Figure 8). Once assembled, the last important step was to use an orbital sander over every surface (Figure 9), making the box comfortable to the user's hands. Voila! The final product is ready for stain or paint (Figure 10).

Outcomes

The major takeaway for me was that the small details of a design are not always needed in order to get started on the fabrication. Due to time constraints, I was cutting the major pieces before knowing how I would make the corner supports and having not decided on the type of fastener. While starting the build, I investigated the options along the way. I wanted to try the biscuit method of connecting, but with time pressure I opted to go to the quicker and known method of the staples, with the understanding that I could hide them as demonstrated. A major lesson learned with any 'first' is time management. Always budget contingency time in the schedule as the time required is often unknown at the beginning. As I approached completion, I had the flexibility to make decisions and pivot as needed depending on the situation.