American Woodworker
Contact Us | Help | Report a Bug
Sign in | Join
 

Nesting Trays Ballwin MO

Prepare your stock, including extra pieces for test-cutting. Cut blanks for the ends (A1, B1 and C1, Fig. A, page 67) and sides (A2, B2 and C2) to length, but leave them 1/8 in. oversize in width. All the ends must be squarely cut.

The Home Depot
(636)207-8875
13929 Manchester Rd
Ballwin, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Woodcraft - St. Louis/Maryland Heights
(314) 993-0413
2077 Congressional Drive
St. Louis, MO

Data Provided by:
The Home Depot
(636)922-1281
6190 Mid River Mall Dr
St Peter, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(636)936-9494
3891 Mexico Rd
Saint Charles, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Rockler Woodworking and Hardware #19
(314) 209-1116
11977 St. Charles-Rock Rd.
St. Louis (Bridgeton), MO

Data Provided by:
The Home Depot
(636)536-0675
390 Thf Boulevard
Chesterfield, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(314)909-7771
10890 Sunset Hills Plaza
Saint Louis, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(314)647-6050
1603 S Hanley Rd
Brentwood, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(314)733-1534
8901 Page Avenue
Overland, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

The Home Depot
(314)865-0700
3202 S Kings Hwy Blvd
St Louis, MO
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 8:00am-8:00pm

Data Provided by:

Nesting Trays

Nesting Trays

Eye-catching and practical, these handy carryalls are sure to please.

by Tim Johnson

Here’s your chance to cut lots of corners and still get great-looking results. These sturdy trays are easy to build, thanks to their simple box joints and template-routed curves. You don’t need a super-equipped shop, just a tablesaw with a dado set, a router table and a drill press. You’ve probably saved enough scrap pieces from other projects to build the trays and the jigs, but even if you buy lumber and plywood, you can make this trio of trays for less than $60. 

Cut the Box Joints

1. Prepare your stock, including extra pieces for test-cutting. Cut blanks for the ends (A1, B1 and C1, Fig. A, page 67) and sides (A2, B2 and C2) to length, but leave them 1/8 in. oversize in width. All the ends must be squarely cut.

2. Arrange the pieces for each box and then mark the bottom edge of every one. When you cut the box joints, these marks will correctly orient the pieces in the jig. 

3. Box-joint jigs index the workpiece for cutting sockets. (Photo 1). Cutting a series of sockets creates the pins. To make the joint, one piece has pins where the mating piece has sockets (see “ Tablesaw Box Joints ,”). 

4. Cut test box joints to dial in a precise fit. This is fussy work, because the tolerances are tiny. The pieces should slide together without binding or rattling. The best jigs have built-in adjustment systems. 

5. Cut all the box joints. On the end-piece blanks, cut sockets only as far as their curved profiles dictate. The side-piece blanks are oversize, so you’ll have to make an extra pass to complete the top sockets. 

Rout the Ends

6. Use the end profile of the large tray (A1, Fig. C, below) as a pattern when you make the routing jig (Fig. B, below). First, transfer the curved edge profile to the jig’s base. Then drill 1-in.-dia. holes with a Forstner bit to establish the ends of the handle hole. Finish rough-cutting the handle hole with a jigsaw. Then rough-cut the edge profile.

7. Smooth the edge profile using an oscillating spindle sander or a sanding drum in your drill press. Install a 3/4-in.-dia. spindle or drum to smooth the handle hole. 

8. Use a large end-piece blank to position the jig’s fence. Each end has six pins. Fasten the fence so the top pins are flush with the base’s curved profile.

9. Install the stops after centering the large end-piece blank. Mount the toggle clamps (see Sources, below).

10. Draw edge profiles and handle holes on all the end blanks after installing them in the jig. Make spacers (W, X, Y and Z, Fig. B) to position the medium and small blanks. 

11. Rough-saw all the curved profiles about 1/16 in. away from the pattern lines. To rough out the handle holes, drill 7/8-in.-dia. holes and use a jigsaw to saw out the waste.

12. Rout the edge profiles with a top-bearing flush-trim bit (Photo 2).

Click here to read the rest of the article from American Woodworker