Nesting Trays North Brunswick NJ
Monmouth Junction, NJ
E Windsor, NJ
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).
Philadelphia Flower Show 2018
Dates: 3/4/2018 – 3/11/2018
Pennsylvania Convention Center Philadelphia
1101 Arch Street
The Philadelphia Flower Show, internationally recognized as one of the nation's premiere events as well as the oldest and largest indoor show of its kind, is produced by the Pennsylvania Horticultural Society. PHS has more than 15,000 members throughout the country, offers hundreds of educational programs year-round, and is considered the nationâ�TMs leading authority on urban renewal through greening. PHS's acclaimed Philadelphia Green program restores neighborhood parks, creates community gardens, conducts large scale tree plantings, revitalizes vacant land, engages thousands of citizens in community development activities and maintains treasured public landscapes. Its greening efforts are modeled in many cities across the country.Not sure if you want to exhibit at or attend the Philadelphia Flower Show 2018? See the panels below to get the information you need to make an informed decision.All information in Events In America is deemed to be accurate at the time we add it,and we take steps to verify all details and update our records when new information is provided, but as people, events and circumstances change, we caution users to independently confirm all information. EventsInAmerica.com and Events In America LLC make no guarantee of accuracy and assume no liability for inaccurate information.