Resistor Storage Box

I made a small, wood­en box using fin­ger joints to store my resis­tors used for elec­tron­ics projects.

A small ply­wood box using box joints

I’ve been hop­ing to prac­tice using box joints for quite a while. My sand­ing acci­dent back at the end of 2019 was in try­ing to make a box joint jig for the table saw sled. When I final­ly did make that, the results weren’t great. So I decid­ed to pur­chase a com­mer­cial box joint jig for a router table from Rock­ler. After a quick test, I also pur­chased some longer, straight cut bits.

Yes, I even make plans for a small box.

The first step was to use my (new!) table saw to cut the 1/2” ply­wood pieces. I also cut the slot in each side to accom­mo­date the 1/4” ply­wood bot­tom. I’m not sure this last step wasn’t a mis­take in my order of oper­a­tions, though. I end­ed up get­ting some real­ly bad treat out from the router on that lit­tle strip of wood on two of the sides. I do think now that a spi­ral down-cut bit may also help with this.

This is why you cut the slot after the fin­ger joints.

So, this box joint jig is intend­ed for a router table. A router table, in brief is used to mount a router upside down below. This then allows you to bring the work­piece to the tool, rather than tak­ing the router to the piece. This is essen­tial in small­er pieces and for many jigs. Now, my router “table” is just a piece of 3/4” MDF scrap I clamp to my work­bench. I can then clamp the jig to that. I used a few more scrap pieces to clamp the shop vac hose as dust extrac­tion. I did sev­er­al test cuts on some scrap to “dial in” the fin­ger width to get a good fit.

My router table is a 3/4” scrap of MDF clamped to my work­bench

After the pieces were cut, I had some repair to do. While ply­wood is a great mate­r­i­al, it’s not the best choice for this par­tic­u­lar method of cut­ting box joints. There was a lot of tear-out. I was able to use some glue & saw­dust to fix some of these before fly­ing up the box. Glue up for box joints isn’t hard, but I could see if being dif­fi­cult on a large piece with all those fin­gers. But it’s at least easy to keep things square.

This was the eas­i­est part.

Once the glue cured, it was time to sand down the fin­gers flush to the box faces. Here again, ply­wood isn’t very for­giv­ing. The thin face veneer sands away quick­ly on the disc sander. Next it was time for wood filler. Those slots left 1/4” holes in each cor­ner. And the ply­wood tear out had numer­ous gaps. So I went a lit­tle crazy with the wood filler. This then left me with anoth­er round of sand­ing. By this point, the birch veneer was com­plete­ly gone in some spots around the fin­gers.

Last­ly, I used the Cri­cut to cre­ate some vinyl sten­cils for the large omega (the sym­bol used in elec­tri­cal engi­neer­ing for resis­tance). The sten­cil worked great, but the adhe­sive back end­ed up pulling off some small veneer fibers. So yet anoth­er draw­back of ply­wood here. The final step was to use some wipe-on gel polyurethane fin­ish. I think maybe doing the sten­cil between two lay­ers of fin­ish would have helped pre­vent the fibers lift­ing.

One of the rea­sons to make this is that it’s not a show piece. This is just some­thing to replace the card­board box I had used for a cou­ple of years to store resis­tors. That way I can learn and prac­tice with no pres­sure. I def­i­nite­ly did learn a lot and I’m not even dis­ap­point­ed in the final result, despite the flaws.

Thinking About John Lewis

We lost a giant among men today. I just watched the doc­u­men­tary John Lewis: Good Trou­ble a cou­ple of weeks ago. Though his life took him from rur­al Alaba­ma, Nashville, Atlanta, and the to D.C., he moved the nation for­ward along his jour­ney. This clip from when he won the Nation­al Book Award gives me some sense of the scale of how far he came in his life.

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Prob­a­bly the best Ama­zon order I ever made

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Let’s all remem­ber the debt we owe Con­gress­man Lewis and more impor­tant­ly, that it isn’t yet paid. Even ‑or, per­haps espe­cial­ly- white folks like me owe him a debt of grat­i­tude. Through his lead­er­ship and non­vi­o­lent protests, he forced us to see Christ in those that do not look exact­ly like us. As this coun­try pulls down mon­u­ments to those whose deeds betrayed the nation’s ideals, let us con­sid­er that stat­ues should instead be erect­ed to those who made the nation greater than the one they were born into.

Pilot Towing Update

Last year, I added a tow­ing hitch to our Hon­da Pilot in order to haul bikes. How­ev­er, it only made sense to go ahead and add the nec­es­sary wiring for pulling a trail­er (brake lights, turn sig­nals, etc.). So I ordered the OEM kit from HondaPartsGuys.com (great site for Hon­da and Acu­ra own­ers!). Again, it warns that this is not a DIY kind of job in the instruc­tions, but it real­ly is very easy to do. The worst part was that I had to remove the hitch, bolt on the wiring sock­et, and then re-install the hitch. Oth­er­wise, it went off with­out a hitch (no, wait, that’s not right).

I got a 7‑pin to 4‑pin adapter (most U‑Haul or oth­er small trail­ers use the 4‑pin as they don’t have brakes and reverse lights). It also has a handy-dandy light tester in it, so I could ver­i­fy the brakes and turn sig­nals both work. A lot of tight spaces to work in, but kudos to Hon­da for design­ing a very easy to install sys­tem here.

IKEA Truck and Trailer
Our Hon­da Pilot tow­ing a trail­er for the first time… to IKEA!

Update 2020-07-18: We rent­ed a trail­er for our trip to IKEA to get some bath­room cab­i­nets & coun­ters.

Rolling Workbench Update

I built the “Basic Mobile Work­bench” fol­low­ing Steve Ram­sey’s design about two years ago. Hav­ing a work­bench on wheels ‑along with the a roll-up exten­sion cord in the mid­dle of the garage- real­ly changed the entire way I make any­thing in the garage shop. But I put some pret­ty tiny lit­tle cast­ers on it, and though it rolled ok, I’d always want­ed to improve it. How­ev­er, since I built it at the height of the table saw, there was not way I could raise. Well, with a new table saw (more to come on that soon), I decid­ed now was a good time to put on some big­ger rollers.

I cut off the legs below the cross mem­bers using my late father-in-law’s old rec­i­p­ro­cat­ing saw. That old Crafts­man is crazy pow­er­ful and made short work of it. I also cut some sup­port bases out of 3/4″ con­struc­tion ply­wood to lev­el out those cuts and give the lag screws some­thing meaty to attach to. The over­all effect was to raise the top sur­face about an inch and it rolls bet­ter than ever.