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As you can see, I use 6-3/8" for the length.
I got this from dry-fitting a set of sides and measuring the length.
I then cut a trial piece and adjusted the fence to be sure. I ripped
the plywood against the fence; with both hands holding the plywood, there
was no hand left to hold the camera. You'll just have to take my
word!
I took a full sheet of plywood and cut it into a
2'x5' slice and a 3'x5' slice. I used the rip fence set at
24". It's hard for me to get a straight cut, so I'll either
take off another thin slice from the cut side or just not use it as a
straight cut for measuring.
After adjusting the fence for the length of the
top/bottom, I rip the plywood to get 2 or 3 6-3/8" slices approx. 2'
long.
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The top/bottoms are 3-3/8" wide. To speed
these cuts I clamp a spacer to the fence. This is a board that I
planed to exactly 1/2" thick. That way all I need to do is add
1/2" to the rip measurement. I can now use the mitre gauge
without as much chance of a kickback. With only 1/2" between
wood and fence it's still possible, so be sure to keep your guard up.
Although sometimes I'll use a push stick to get the cut piece out, I think
it's safest to wait until the blade stops before removing it. A few
pieces with saw-marks bouncing around the room reinforces that idea!
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I make a trial cut with one board. I then check
to see it fits both the top and bottom. Since the bottom is not in
view, I'm not as picky about the fit (I don't claim to be a master
woodworker!) . It's more important that the mitre cuts close
up tightly with the top in place.
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Assuming everything fits, I cut the rest of the
pieces (16 for the 8 boxes). To save time I'll stack the plywood
slices and cut 2 or 3 at a pass.
I raise the blade a little higher than the gullet
for these. With the blade coming down at a sharper angle, the cuts
are clean and there tends to be less kick back at the rear.
At some point the pieces need to be sanded.
The best time to do this is before you cut the tops/bottoms. I
remembered about half-way through. Trust me, it's quicker to sand
the large pieces than the smaller ones. You will still need to sand
the edges after the cuts, but this can be done at the end. If the
dados are a little tight you'll need to sand down the edges to get a
smooth slide anyway.
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After all the pieces are cut I stack and put them away
for the assembly. |
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