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Nesting Trays Seymour IN

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.

Brownstown Our Own Hdwe
(812) 358-4038
110 S Main St
Brownstown, IN
 
North Vernon-Auth Hometown
(812) 346-2808
247 E Walnut Street
North Vernon, IN
Store Hours
Hometown Dealers
Store Type
Hometown Dealers
Hours
Mon:9.5-19
Tue:9.5-19
Wed:9.5-19
Thu:9.5-19
Fri:9.5-19
Sat:9.5-19
Sun:14-19
Store Features
Mon:9.5-19
Tue:9.5-19
Wed:9.5-19
Thu:9.5-19
Fri:9.5-19
Sat:9.5-19
Sun:14-19

256 Supply True Value Hardware
(812) 794-6256
330 W Main St
Austin, IN
 
LOWE'S OF COLUMBUS, IND.
812 376-0521
3500 10TH STREET COLUMBUS, IN, 47201
Columbus, IN
 
Brands, Inc.
(812) 379-9566
1425 California Street
Columbus, IN
 
Lucas Ackerman True Value Hdw.supply
(812) 358-4552
300 N Main St
Brownstown, IN
 
Goecker Bldg Splys True Value
(812) 346-3627
2885 N State Hwy 3
North Vernon, IN
 
Lowe's
(812) 376-0521
3500 10Th Street
Columbus, IN
Hours
M-SA 6:30 am - 10 pm
SU 8 am - 8 pm

Kmart 3741 / Cross Merch
(812) 372-7863
2394 25Th St
Columbus, IN
Store Hours
Miscellaneous
Store Type
Miscellaneous
Hours
Monday To Friday Working Hours is :8-22 and for Sat:8-22
Sun:8-21
Store Features
Monday To Friday Working Hours is :8-22 and for Sat:8-22
Sun:8-21

The Commons Mall
(812) 379-1400
222 Commons Mall
Columbus, IN
Store Hours
Sears Stores
Store Type
Sears Stores
Hours
Mon:10-20.5
Tue:10-20.5
Wed:10-20.5
Thu:10-20.5
Fri:10-20.5
Sat:10-20.5
Sun:11-21
Store Features
Mon:10-20.5
Tue:10-20.5
Wed:10-20.5
Thu:10-20.5
Fri:10-20.5
Sat:10-20.5
Sun:11-21

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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