SHOP PROJECT

ChiselCase
This caseprotectsyotn favorite chisels
and doubl"es
asa
workingchiselstand.Insteadof complicatedjoinery,thisprojectrelieson
a precisefit andunderstanding thenaturalmovementof wood.

.r
I havea fondnessfor uniquecontainers.That'swhy should occur will not open any of the joints or cause
L lam intriguedwiththisproject.Itnotonlyholdsand cracksto develop.
protectsthe chisels,it's alsoa working displaybox. roIrqBnv.While thejoinery in this projectis not com-
The fact that we used this box for chisels doesn't plicated, precise fits are very important. For most
mean that it wouldn't work equally well for a set of pieces,I recommendthey be cut oversized,and then
knives, or by removing the dMders, it could hold a trimmed to fit.
specialbook or housethe family album. woon. When choosingwood for the case,try to use
ENDGRATN. Since the toleranceson this case are hardwoodsthat havebeen kiln dried. No matter how
verytight,I hadto paycloseattentionto the movement carefully the caseis constructed,using wood with a
of the wood asit expandsandcontracts(with seasonal high moisturecontentwill causeproblems.
changesin humidity). To prevent problemswith the I built this caseout of walnut. The handles on the
wood splitting,the grain of all the piecesshouldrun in chisels are light colored and the dark background
the samedirection. makesthem standout. Walnut is stableand relatively
While it may seemlike alot of extra work to dealwith easyto workwith.
all of the endgrain pieces,the result is well worth it. All FINISH.After completingthe case,the interior and
of the grain in the case runs in the same direction, the exterior were finished with three coats of hand-
almostasifthecasewerehollowedoutof a singlepiece rubbed tung oil. If you feel you need a more durable ,A\
of wood.By doing this, any movementin the casethat finish, polyurethanewill offer more protection.

Woodsmith No.63
EXPLODEDVTEW MATERTALSI.IST
LID PANEL TR.AY
A End Blocks(2) l1/2x9V4-7/B
B Cose Dividers(7) l/av l1/2-lll/a
C BottomPonel(l) t/ax9Va-12V2
D Chisel Rests(6) 3/4x 11/4- 1/2

UD
E Lid Ponel(l) t/ax9Va-121/z
F LidSides(2) 1/ax2- 12Vz
G LidStiffener(l) 3/ax91/a-Vz

CUTTING DIAGRATI
1/4" x 3r/2" - 36" (.9 5q. Fr.)

t/4" x 5" - 38" ( I .3 5q. Fr, Eochl

E tr
F

SUPPTIES
LUAABER
r 3.5 Sg.fi, 7a"-thickwolnut
o .6 Boordff, 3/a"-thick
wolnut
HARDWARE & FINISH
r (2) No,l2x I 7a"Rhbrosswoodscrews
. Tungoil
. Postewox
cRosssEcTroN

LAY OUT THEEND BTOGKS

I slarted work on the chisel caseby deter- ber of chiselsyou have.(I havesix chiselsso a blank l0rrwideby 8rrlong,seeFig. 1.
mining thewidth of the end blocks (A). The 6xl774tt=7Vzt.) When the glue is dry, trim both endsand
width dependson three things: the width of Also, determinethe total thicknessof the then cut off a 6rllong piece,leaving a 17arl
your widest chisel, the number of chisels, tray dividers. (SinceI used sevenV+rr-thick piece,see Step 1. (Savethe short piece for
and the thicknessof the tray dividers. dividers the total thickness of all of the later use.) Now, rip the 6'r-longpieceto the
DETERMINING TIIE WIIIH. MeasuTethe dividersis 13l+rr.) finishedwidth for your end blocks (9Vlrr).
widestpartofyourlargestchisel,addVsrrfor Now, add the total width of the tray sec- To get the thicknessneededfor the end
clearance,and this will be the width of each tions (7/zrr) and the total thickness of the blocks,cut the 6rLlongpiecesin half andglue
bay section.(Thelargestchiselin my set is dividers (13l+")to get the total width (9V+'r) these two pieces together face-to-faceto
178rrwide, soeachtray sectionis 1Vtrrwide.) of the casetray (andthe end blocks). form a block,seeStep2.After the glue dries,
Once you know the size of each section, ENDBIrcKs.To makethe endblocks (A), cut this block to get two end blocks (A) 97+'l
you can multiply that figure times the num- I edge-gluedenough3/+rLthick stockto form wide by Tsrrlong, Step3.

FIRST:rocr GruETwo SECOND:cur 6" PIEcE

lN HArF, THIRD:cur ro FoRm
rwo
Ve" x 5" - 8n BOARDS, rHENSTACK
ANDGI.UE TOGETHIR ENDBTOCKS
78" LONG
CT'I OFF 6" PIECE,
THEN RIP TO 9V4"

RIPEQUATAMOUNTS

No.63 Woodsmith
GUTTINGTHE OROOVES
After making the CUTITNGTTIE GRoovEs.After the rabbets saw fence so that it acts as a stop for your
end blocks, V+ttrap. are cut, divide the spacebetweenthe rab- next cut. After cutting the firstgroove, turn
betsandgroovesare bets into six equalspaces(or the number of the pieceendforend andcutanothergroove
cut to hold the case chisels in your set) with a V+rrgroove be beforemoving the fence.Repeatthis proce-
divider(B).(Cutthe tweenthem, seeFig. 3. Now movethe table dure until all ofthe groovesare cut.
rabbetsandgrooves
to match the actual
thickness of the
dMders.)
sE'rrrIE DADonr-lln. Begin by setting the
saw to cut a V4ttx V+ttrabbet.To do this,
attacha woodenfenceto your table sawrip
fence,seeFig.2.I alsousedawoodenexten-
sion on my miter gauge.The extensionsup
ports the pieceand helps preventchipout.
Now setthe rip fenceto actasa stopandcut
a rabbeton both endsofthe endblocks(A),
seeFig. 2.
Note: These rabbets(and the grooves
thatfollow)mustbecutintoendgrainon the
end blocks(A).

DTVTDERS& BOTTOTI PANET

With the end blocks sanderor a sandingblock. Notes,page12.The finished sizeof the bot-
(A) completed you ASSEMBLY. After the dividers have been tom panelis the sameas the outsidedimen-
can begin work on sanded,fltandglue them into the groovesin sions of the tray that you just glued up, see
the case dividers the end blocks, seeFig. 6. (Make sure that Fig. 7. (Our divider tray measured9V+ttx
(B). Startby ripping this assemblyis squareand that it sits flat.) l2Vzn.)
Bc[x)M pANEr.After the dividers (B) are
V a r sr t o c k f o r t h e Now glue the bottom panel (C) to the
dividersto width. gluedintothe endblocks(A),you canmake divider tray. Use glue sparingly to avoid
RIP TO WIDTH. To the bottom panel (C). squeezeout. Make sure the edges of the
determinethewidth Start by edge-gluingenough 7+"-thick bottom panel (C) are flush with the sidesof
of the dividers, measurethe lllckires.s stock to make the bottom panel,seeShop the tray dividers (B) andthe endblocks (A).
(height) of the end blocks (A) and rip the
dividersto that width. (ln my casethat
measurementwas IVz".)
DETERMINETHE r-ENGTH. After the pieces
have been ripped to width, I cut all of the
dividersto the correctlengthfor my chisels.
To determine this length, measureyour
longest chisel and add3/+tt.(fhe extra 7+rl
allowsfor the 74rrgroovesin the end blocks
(A) and a V+ttof clearancewithin the case.) reiu't"J#J,fi:f.,
IAYTNGOIJTTIIE ARC.AftEr the dividers
(B) havebeencut to length,lay out a shallow
arc to allow clearance.topick up the chisel.
Begin by laying out the arc on one of the
dividers. To do this, mark points 15lg'rin
ftom each end of the divider along the top
edge,seeFig.4. FTUSHENDBIOCK
To drawthearc,Lapethedividerto a scrap
pieceof plywoodand drive a coupleof nails
alongsidethe two marks on the divider, see
Fig. 4. Then bend a piece of posterboard
insidethe nailsandadjusttheapexofthe arc
so it's %rr from the opposite edge of the
divider.Then draw the arc.
cUTnNG TIIE ARc. Next stack all of the NOTE:
dividers with the arc on top and wrap the DIVIDER
stack with masking tape,making sure that
the edgesandendsareflush,seeFig. 5.Now
cut closeto the layoutlinewith the bandsaw, AND END BTOCK
and then sand up to the line using a drum

10 Woodsmith No.63
tID ASSETIBIY
After the tray as- Now set your saw blade at 30' and cut a Vzttfromthe bottomend,seeFig. 10.Then.
sembly is complete pieceoff the panelthat's the length you just drill a Tsrrpilot hole through the lid sides(F)
you canbegin on the determined,seeFig. 8a. andinto the endblocks (A), seeFig. 10.Nou-
lid panel (E). Start Next, placethe short pieceon the caseso removethe carpettapeandenlargethe hole
bygluing up enough the long beveledpoint is touching the arc. in the lid sides(F) Lo7/3ztt.
stock to make a Now mark andtrim the end flush, seeFig. 9. Before screwing the lid sides (F) to the
panel that's V+' uD sIDEs.To makethe lid sides (F), start casetray,placea Vazrr shimbehindeachlid
wider and |r longer by measuringthe thickness (height) of the side (F). Now tightendowna No. 12round-
case.Then rip two piecesof Varrstockto that
than the trav. After it headscrewuntil the bottomofthe screwslot
dries,rip the panelTrorrwiderthan the tray.measurement(2rr)andcutthemto the same is flushwith the lid sides(F), seeFig. 10a.
ASSEMBLETIIE POCKET. NCXI, tO fOTM thc length asthe case,seeFig. 9. ASSEMBLE TIIE uD. Next, fit the remain-
pocket and lid top, cut the panel into two After the lid sides (F) are cut, fastenthem ingpartoftheiidbetweenthesides,andtrim
parts,seeFig. 8.To determinethe length of to the tray with double-sidedcarpettape. the end flush with the top of the case,see
the pocket,measurefrom the endof the tray, HINGEScREwS.With the sides in place Fig. 9. Then glue the panel to the lid sides
to wherethe arc beginson the divider.Then you can drill the holesfor the hinge screws. (F) only.When the glue is dry, file the screw
addVz"to allow for trimming. First, drill a 3/8r'counterbore,Vto|deep and headsflush,seeFig. 10a.

q. 2tta" I9THE TO TOPPANETONIY

<\. t. r t \'
.\
\xK'..-* \\ \\'\'

SET SAW BTADE TO 30'

AI"IGNBEVET
WITH ARC
SCREW

TOOL RESTSAND tTD SflFFENER

Once the lid is completed,round over the to Fig. 1),usea 3/8rr
round-overbit androut a stiffener (G) to fit betweenthe lid sides (F),
sides (Varlround-over)and ends (Vz"round- bullnoseon both ends,seeFig. 11a. see Fig. 12. Finally, glue the pieces in as
over),refertoFig. 12.Thenyoucanbegin on cuT To FIT. AJter the bullnoses are shownin the CrossSectionon page9.
the chisel rests (D) and tid stiffener (G). complete,cut off two Vzrllongpieces, see FINGERRECESS. The last step is to file a
RourINGrIrE nncn. Using the cut-offleft Fig. 11.Now, cut the chisel rests (D) to fit 3/4t'-widefinger recessin the bottom end to
over from making the end blocks (A) (refer betweenthe casedividers(B), andcutthe lid make a lip for openingthe lid, seeFig. 12.

cllPE-L-3::-r -iuiiolii
nouNloven,o4

uD cAsEDrvrDERs Za -A< /\ tlDslDEs

CHISEIREST NOTE:RouND ovER ENDS

AND EDGES
wlTH CASECTOSED

No.63 Woodsmith