Making a One Piece Box on the Router Table

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Making boxes with the router is argueably one of the most fun things you can do with a router table. Not only that, you get to turn out objects that almost everybody loves and can use ... and it makes you look great. The other thing with boxes on the router table is by taking a design like this and modifying the sizes a little bit, you can make a whole range of different sizes, with or without hinged tops and all sorts of different and unique add-ons. Boxes are one of the most popular items for many people because they look great and are functional. They can be varied in so many different ways, different woods, contrasting woods, stains and dyes, final finishes, glossy, satin, matte, or by making them from laminated veneer woods and highlighting with contrasting wood, the variables are endless.

In this article we are making what we call the One Piece Box because it can be made from on piece of wood. The finished box is 4 inches square and if you  can make it either with a routed lift off top as shown in the video, or you can leave the top on and cut it off on your table saw, then use hinges to open the lid. To make the 4 inch by 4 inch box, you need to start off with a board that is at least 26 inches long and 4 inches wide, by three-eighths of and inch thick.

In terms of tools, you will need a router and router table with a fence and you will also need a rabbeting bit that can be set for 3/8" (this is normally done by selecting the correct bearing on top) and you will need a spiral bit, you can use a 1/4" but will find that a 3/8" spiral bit is slightly more forgiving when it comes to cutting the top off the box. The 1/4" will work fine, just make sure you are absolutely correct with your cuts.

Touring of a Bit and Blade Sharpening Shop

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We often don't get the opportunity to see "behind the scenes" tours of businesses that we deal with on a regular basis, but today, we are making an exception. We have not only a behind the scenes look, but and actual guided tour of a bit and blade sharpening business called "The Edge". We get to see what the machinery looks like that sharpens our bits and blades and how it is use.

In this video you will get to see a variety of sharpening machinery and tools and in some cases we will get to see how they work and what they do. Our tour guide is sharpening expert and The Edge Owner, Tom Saxby, who has a remarkable sense of what it takes to provide sharp blades for specific needs at competitive prices. In this video we will get to see what a spiral sharpening machine looks like and how it work, we will see how blade sharpening machine for jointer planers works and including a variety of blade sharpening machinery.

There are two very fascinating machines that are particularly interesting. One is the CNC saw blade sharpener the other is a machine that actually makes shaper type blades.

Pattern Making with the Router

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Learning the tricks of how to use tools can make your woodworing life so - much - easier. The router is one of the perfect tools for making multiple, identical parts or components. Of course, you normally would need a router table with this as well, but depending on the part and the size, these can be done free hand, as long as the parts are held down firmly, and it's a great opportunity to use a "starter pin" to ease the wood into so that it makes a smoother transition.

In terms of a bit, a flush trim bit all that is needed. There are a few versions of these bits in both 1/4" and 1/2" shanks. You can get bits with bearing at the top of the bit, or at the bottom of the bit and you can even get some with bears at both top and bottom. The bits with the two bears are best because it gives you more options.

The actual template material that works best is 1/4" hardboard which is readily available at most hardware and wood supply stores. Although there is also a 1/8" version, which is also painted white on one side and is very nice for drawing your template outline on, the thinner version means more risk of running off the template which can ruin it, and your work piece.

The finished wood products from using this pattern making method are smooth well shaped products that are ready for the next step in the production of the finished product.  Pattern making can be used for a variety of woodworking projects but one of the best uses is in making "blanK" inserts for your table saw.

Sharpening Drill Bits with Drill Doctor

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There is nothing more annoying than trying to drill some accurate holes in a project and having the holes all ragged, or even worse, having them off centre because the drill bit is dull. I'm always amazed at home many times we drill holes in things, no wonder manufacturers are always coming out with newer and better corded and cordless drills ( and drill presses too). Woodworkers are a lucky bunch, we can use almost any drill bit to drill wood and most will at least do an acceptable job ... that is ... if they are sharp.

Of course the most common drill bit is the simple twist bit. Certainly it is not the oldest type of bit, in fact it really only came along with the introduction of powered tools to drive a bit of this design. Prior to power drills we had to use braces and similar tools with auger and spoon bits to drill holes. But twist bits remain the most common, though not always the most ideal for the job ... but none the less, the most common because they can drill wood, metal and plastics. Other bits like auger bits, Brad point tipped bits and forstner bits are pretty much only for wood.

There have been tools and jigs around for many years that can be used to sharpen twist bits, but we have not found any that are easy and convenient to use. To sharpen twist bits you really need a dedicated machine, and thats precisely what Drill Doctor has done. They have introduced a line of sharpening tools that will sharpen a long list of twist bits and some Drill Doctor tools will even  Masonry bits.

The Drill Doctors are easy to use and will produce consistent results of sharp drill bits. If you find that the diamond grinding grit wheel in your unit is becoming warn, it is easily replaced with either a 100 grit or 180 grit wheel for finer grinding points.