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Nesting Trays La Grande OR

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.

Millers Dib Home Ctr & Lumber
(541) 963-3113
307 Greenwood Street
La Grande, OR
 
D & B Supply
(541) 963-8466
10101 E 1st Street
La Grande, OR
 
Bare's Hometown Hardware
(541) 562-5472
206 S Main St
Union, OR

Data Provided by:
Northwest Timber
(541) 327-1000
3229 Jefferson-Scio Dr, SEPO Box 1010
Jefferson, OR

Data Provided by:
The Home Depot
(503)289-9200
1728 N Jantzen Beach Ctr
Portland, OR
Hours
Mon-Sat: 6:00am-10:00pm
Sun: 7:00am-8:00pm

La Grande - Auth Hometown
(541) 963-8451
1700 Portland Ave
La Grande, OR
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:9.5-18.5
Tue:9.5-18.5
Wed:9.5-18.5
Thu:9.5-18.5
Fri:9.5-18.5
Sat:9-18
Sun:11-16
Store Features
Mon:9.5-18.5
Tue:9.5-18.5
Wed:9.5-18.5
Thu:9.5-18.5
Fri:9.5-18.5
Sat:9-18
Sun:11-16

Hometown Hardware
(541) 562-5472
206 S Main
Union, OR
 
Gilmer Wood Company
(503) 274-1271
2211 NW Saint Helens Road
Portland, OR

Data Provided by:
Woodcraft - Portland, OR
(503) 684-1428
12020 SW Main Street
Tigard, OR

Data Provided by:
The Home Depot
(503)861-9999
1650 SE Ensign Lane
Warrenton, OR
Hours
Mon-Sat: 7:00am-9:00pm
Sun: 8:00am-7:00pm

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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).

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