Author: Jason Coleman

So, if you hap­pened to read my post last month on injur­ing myself, you’ll recall I did so because I was hop­ing to make a box joint jig. A box joint, or as it also known: a fin­ger joint, is a series of over­lap­ping “fin­gers” along a joint. This style of join­ery gives lots of glue sur­face area as well as shear strength to a cor­ner joint. It’s com­mon­ly used for the cor­ners of a box, thus the name.

Well, I did man­age to make a first attempt at a jig and made a sin­gle joint test. I was hop­ing to use my stan­dard table saw blade with my sled in lieu of pur­chas­ing a dado stack1. The jig is a bit too loose in the cuts and it’s pos­si­ble my table saw sled is a bit too loose in the miter slots, as well. This com­bined with some cheap­er birch ply­wood (there are lots of voids and a very thin veneer) result­ed in the fin­gers look­ing more like a box­er who’d just fought Mike Tyson.

Also, the depth of the cuts were a bit too deep (which is easy to adjust, at least). But glu­ing up the loose joints was a mess.

I had sort of giv­en up on the exper­i­ment as a fail­ure, but I did recent­ly go back and sand the fin­gers down; this time on pur­pose (yeah, I get the humor after last mon­th’s inci­dent). The joint still does­n’t look great but it was­n’t as “gap‑y” as it seemed before cleanup. What’s more, I can attest that even as poor as this one looks, it is incred­i­bly strong. It’s not espe­cial­ly pret­ty, but for some util­i­ty box­es, it would def­i­nite­ly serve it’s pur­pose.

So, this was­n’t a total fail­ure and I did learn a lot from the exer­cise, includ­ing the injury. Which, my fin­gers have com­plete­ly healed back, nails and all. As a result of “baby­ing” the left index fin­ger, I did devel­op ten­donitis in my left elbow (which is real­ly the fore­arm mus­cles and ten­don con­nec­tion). So, that lit­tle inci­dent con­tin­ues to remind me to be safe!

1. A dado stack is a pair of blades, often with inter­me­di­ate spacer/chippers in between which cut out a wider sec­tion of mate­r­i­al in each pass on a table saw. [↩]

A few years ago when I was con­sid­er­ing get­ting into more “fine” wood­work­ing, there was one project that came to mind: recre­at­ing the foot­stools my grand­fa­ther, Cicero, used to make. He was a handy wood­work­er and built a lot of use­ful projects1 I know we had two or three of these foot­stools around the house grow­ing up. I assume my aunts and cousins may have had some, as well. They’re per­haps not a mas­ter crafts­man project, but let’s not over-esti­mate my abil­i­ties. As my mom put it, though, after about a half cen­tu­ry, they’re still in use!

So in 2016 I sat down to care­ful­ly draw out the pieces. His were all made from 1″ thick sol­id pine, but I fig­ured I’d use 3/4″ ply­wood instead. The legs and sides have a rough­ly 10° slant such that the base tapers up to give a slight lip all around the top footrest. I also decid­ed to add a hand­hold to the top of mine (some oth­ers of his may have this, but the one that sits in our kitchen does not). On my notes and sketch­es, I also doo­dled out a logo that read “Cicero Hand Made Crafts. Est. 2016”. I fig­ured he was the “mak­er” in my fam­i­ly so I’d hon­or that by label­ing made items with his name.

It took me about a year-and-a-half until I actu­al­ly got around to mak­ing my first foot­stool. I batched out the pieces on the table saw for two foot­stools from a 2’x4’ project board of 3/4″ maple ply­wood. Some of the angle cuts using my cut pat­tern result­ed in a col­or mis-match in the wood, but this could prob­a­bly be resolved by buy­ing high­er qual­i­ty ply­wood in the future. The band­saw was used for all curves, includ­ing cut­ting the arch­es in the legs at 10° (so they’re actu­al­ly lev­el when assem­bled). I used the drill press and a 1 5/8″ forstner bit to hog out mate­r­i­al for the han­dle (which I then cleaned up with a series of rasps, files, and sand­pa­per). The disc and belt sander were used to clean up all the edges (with care not to remove any more fin­ger nails). My super-sim­ple router table was used to add a 1/4″ round-over to edges. I then used the ran­dom orbital sander to clean every­thing up.

I used made an assem­bly jig for the first piece and used pock­et holes to attach the legs to the top (some­thing my grand­fa­ther did­n’t have but he seemed like a prac­ti­cal enough per­son, he’d have used them if he could have). I attached the side run­ners to the legs with some counter-sunk wood screws (black). I used a light col­or wood filler for any ply gaps (or oth­er blem­ish­es). Final­ly, a gen­er­ous coat of wipe-on polyurethane was applied for a fin­ish.

I assem­bled the first foot­stool as a Christ­mas gift for my old­er broth­er last year and then com­plet­ed the sec­ond foot­stool as a Christ­mas gift for my mom this year. The process for build­ing both pieces was a learn­ing curve, so I did­n’t real­ly take great pho­tos of either build. These are a mix of both projects (which is why the tops look dif­fer­ent). I already have planned out mak­ing some addi­tion­al tem­plates to use with a trim router to help improve the process for future builds. This project is so great because it ends up using almost every pow­er tool I have. But just like every project I try, there is always some­thing new to learn even when I’ve already built the same thing before!

1. One of which was a long shelf for my dad’s hi-fi sys­tem; a gift to his new son-in-law. This lat­er became the plat­form which our G.I.Joe USS Flag air­craft car­ri­er play set lived! [↩]

I got a hard les­son deliv­ered today while start­ing a project in the garage this after­noon. I’ll lead in with say­ing that I’m ok (and will heal up fine in a week or so); only a bit rat­tled. Let me start with where my head was (and should­n’t have been) that got me here.

I’ve had on my “To Do” list for 2019 to learn how to make box joints. Well, here we are into Decem­ber and I’ve not even tried it. I had want­ed to spend last Sat­ur­day work­ing on it, but I let the week­end get away with me with Thanks­giv­ing and Christ­mas dec­o­ra­tions (which are fine and I was glad to get the time I had with all my fam­i­ly). This evening, I had a Cub Scout event with my son in which I was respon­si­ble for bring some audio and video equip­ment (i.e., our home AV receiv­er, speak­ers, and disc play­er). That end­ed up tak­ing a lot longer than I had antic­i­pat­ed. But I had an hour to spare so I fig­ured I’d at least get a jump start on my box joint jig, know­ing all day Sun­day (tomor­row) is going to be busy with oth­er things.

And it’s entire­ly worth under­scor­ing here: this is all arbi­trary pres­sure I’ve put on myself. Absolute­ly no one else cares if I fig­ure out how to make box joints ever, let alone today or even this year. But I had con­vinced myself that I need­ed to rush through the hour to get the table saw jig set up.

I picked out my back­ing board and was look­ing for a piece of scrap that approx­i­mate­ly the same thick­ness as my table saw blade kerf (sim­ply put, that’s the width of the cut that the table saw makes and is frac­tion­al­ly wider than the blade itself). My ini­tial plas­tic piece for the jig end­ed up a big loose the back­ing board, so I want­ed to quick­ly try a dif­fer­ent approach. Mind you, the piece I’m try­ing to cut is less than a 1/4″ thick. So I fig­ured, why not start with a thin off cut and just sand it down to the nec­es­sary thick­ness?

My pow­er sander is a com­bi­na­tion of a belt sander and 6″ disc sander. The disc of course will put a twist on any object pushed into it, so a firm grip and just being mind­ful of one side lift­ing and the oth­er push­ing down is impor­tant. I grabbed a long thing piece of scrap and tried sand­ing it on the disc, not think­ing about where my hands would go if (when) it slipped out of my grip. I also failed to put on gloves. You cer­tain­ly do not wear gloves with some pow­er tools (any­thing with a cir­cu­lar spin­ning blade), but they are a good idea with a sander.

With­in less than a sec­ond of me push­ing the wood into the disc, it knocked it right out of my hand and left me push­ing my fin­gers into the sand­ing disc. Now, in all the pow­er tools I have, if I had to pick one that I was going to injure myself on, it would prob­a­bly be the pow­er sander. Blades, as you can imag­ine, can quick­ly cut into flesh and cause seri­ous injury or death. I can­not imag­ine sus­tain­ing a life-threat­ing injury on a small pow­er sander like mine (though I’m not say­ing it’s impos­si­ble). But at 3600 rpm, 120 grit sand­pa­per can remove skin and nails quite rapid­ly. Cer­tain­ly faster than my reac­tion time. Before I knew it, my unnec­es­sary rush and lack of think­ing about what I was doing caused me to injure my index and mid­dle fin­gers on my left hand. My mid­dle fin­ger got the skin scraped bad­ly but my index nail is about 1/4″ too short now. And boy howdy is that sen­si­tive skin under there!

Again, it’s noth­ing seri­ous. I was able to turn off the machine and imme­di­ate­ly go treat it myself. My fin­gers are sore but the nail should grow back. Hon­est­ly, it’s the les­son I need­ed to learn. Pow­er tools are not any­thing to be in a rush around. Every action with one requires com­plete focus and atten­tion. I need to always think about how the tool could injure me based on the action the tool makes. Giv­en that I was also using my band saw and table saw today (which, I do take less for grant­ed, to be fair to myself), I’m for­tu­nate that this is the injury I end­ed up with.

As my kids join me in the shop more, I’ve had to teach them lessons about safe­ty. I’ve even had to warn my son about touch­ing that very sand­ing disc until it comes to a com­plete stop (he thought he should stop it spin­ning one day after I’d killed the pow­er). I even recent­ly watched James Hamil­ton’s (aka, Stumpy Nubs) video on injur­ing him­self with an angle grinder and remarked on the need to pay atten­tion when I’m work­ing. I firm­ly believe that the num­ber one most impor­tant piece of safe­ty equip­ment is your brain. Too bad I failed to put that and my gloves on this after­noon. I’ll do my best to take that les­son to heart from now on.