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| Router Bit Box - Page 2 |
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| Written by Charley | |
| Friday, 06 September 2002 | |
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Assembly... Assemble the base first. Take the two 170mm sides and attach them to one of the MDF sheets, by sliding the MDF into the dado's as shown in the picture (right). Then place glue on the ends of the sides (also shown in the picture on the right).  (click photo to enlarge) Now place one of the 400mm sides over the glue, making sure the MDF slides into the dado and that the 170mm sides are flush with the ends. Pre-drill holes through the counterbores you drilled earlier then drive some screws into the holes. Repeat this step and the step above with the other side.  (click photo to enlarge) You need to make some plugs now. You can do this with a 10mm plug cutter or, if you haven't got a plug cutter you can use some 10mm dowel. These are to go into the couterbores to cover the screw heads.  (click photo to enlarge) Add a drop of glue into the counterbore (over the screw head) then select a plug, trying to match up the grain. Once selected, hammer the plug in. Repeat this with all the other holes.  (click photo to enlarge) Once the glue has had chance to dry, its time to trim the plugs flush. You can do this with a chisel. Hold the chisel firmly and take off thin strips in a paring action, it helps is you slice with the grain!! Once the base has been assembled repeat all the assembly steps with the top pieces.  (click photo to enlarge) Once the top and base have been assembled sand all surfaces. We started with 80G then 120G and finished with 320G.  (click photo to enlarge) We selected a mahogany finish which we put on with a foam brush. Three coats with a light sand in-between coats should be fine!  (click photo to enlarge) Select your choice of hinges and catches.As you can see in the picture (right) we chose a butterfly hinge.  (click photo to enlarge) For finishing touches we added four plastic shelf supports to act as feet, they work really well!!  (click photo to enlarge) Here they are finished. You might wonder why we have two? It's just the day I (Charley) finished my router box, Tom came down for the weekend and he wanted one for his router bits, so we decided to build another one for him and upload the steps to the website. His is the lighter of the two - it had only had two coats of stain when the photograph was taken.  (click photo to enlarge) To really finish the box off you can add some foam to the lid (to protect the cutters). As you can see in the picture (left) we've added blocks of wood to hold the router bits in, all you have to do is cut some timber down to the right size (we used hardwood) and drill holes for the bits. You need a 7mm drill bit for 1/4" shanks and a 13mm flat bit for 1/2" shanks. We're really glad we made this project as it's very handy and it keeps our cutters safe. No doubt we will be making a larger one in a couple of years when our collection of bits grows. We hope you have fun building this and find it as useful as we have...  (click photo to enlarge) Go to: page 1 |
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