Box Designs
Top/Bottom - 405mm x 328mm
Side(s) - 328mm x 495mm
Front/Back - 400mm x 484mm
Jig Saw Process.
I was nervous using the jigsaw as I didn’t want to go over the lines I had drawn out. One idea came to mind to drill holes at each corner so there would be a marker to aim to.
Like the Hole saw, I practiced a few times to make sure I was happy enough to work on the real piece I was going to use. I did also decide that I would trim away at the edges slowly as to not cut off too much. And to also file/sand away any bits that I could not do myself.
After the second side I started to become more confident with my cutting, I did struggle with some of the corner pieces and some of the side near it, but I decided instead of risking cutting too much off to just sand those bits down afterwards.
Health and Safety.
Material and Equipment used :-
- OSB Board
- Screws
- Wood Glue
- Jigsaw
- Circular Saw
- Drill
- Hammer
- Clamps
- Tape Measurers
- Sand Paper
- Angle Grinder
Safety Equipment Used: -
- Ear Defenders
- Strong Shoes
- Safety Guards
- Clamps
- Face Shield (For Angle Grinder)
Since I did not have much experience before making the prototype box, I was supervised nearer the beginning to make sure I was using the equipment safely and correctly. I also worked outside as I then had more space to work and move around and so also have a well ventilated space.
Process - Cutting the Shape.
When building and cutting out the box itself I used millimetres, as it has more accuracy when re - measuring sides. When I was cutting the wood to shape I had to place another piece of wood to the piece I was cutting as a sort of ruler to make sure the line was straight. And so I had the line that was to be cut and then another line 34mm away for the ruler as that was the distance needed in order for the saw to cut accurately
Building the Box.
This part was tricker than I thought as I had to keep certain sides in place in order for me to attach them together. And so for this bit I did require a second set of hands to hold the wood in place until the structure itself could stand without help.
There were some sides that I forgot to add the wood glue to, and so I had to remove the screws for I think two of the sides. I did leave the glue to dry a little before attaching the wood together as with it being tacky it doesn’t ooze out as much.
The Box (In Progress).
Torch Holder Development.
To make the hole for my torch, I used a pillar drill to make an accurate enough hole for the torch. I did have to change the height of the wood block so that I could make the hole go all the way through. Although the drill bit had to be changed halfway through as the hole itself was not the right size.
I lined up the holes so the torch could fit accurately, I did need someone to hold the piece of wood in place as I could not reach round to the hole in the side. Two screws were enough to hold it in place but to make sure it would not move around and for design purposes an additional two screws were added.
I then used a bevel to sand down the torch holder and hole so that they matched up and also for it to be smooth.
Starret Holesaw Process.
To make the hole where the torch would sit I used a Starret Holesaw to make the circle as accurate as possible. The image below shows a few practice holes I did to ensure I was comfortable using the drill.
For the actual piece I drew out where the hole would go by finding the centre of the wood panel. It didn’t take me long to start as you can place the drill head where you need it to be as it drills with that part before the circular piece hits it. For the practice pieces and for the actual side I did have to flip the wood over as it prevents tear out on the other side. Another way to prevent this is to drill on another surface but I did not want there to be a lot of wasted wood if I could help it.
Building the Box.
Sanding.
The wood that I used is quite rough and can splinter easily, so to avoid this from happening and to make it have a nice finish I sanded down the inside and outside of the box, producing a smooth, pale finish you see below.
I did then use the angle grinder to remove any screw points that were protruding out the wood for health and safety and to have a nicer finish on the inside of the box.
Hinges
For the door I cut one side of the box in half, I think it would’ve been better if I had cut two bits of wood separately to eliminate the possibility of one being bigger than the other. But I am happy with the size it came out.
The hinges that I had were too long for the actual door, and so to get round this problem I attached the hinges to a clamp and bent the hinges round for it to sit on the other side of the wood. I will have to cover up the parts where the paint came off from the bending but I will wait until I add additional detailing.