The Eleven Grooved Box

MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... [THUNDER] [CAR ALARM BLARING] WHEN THE UNEXPECTED HAPPENS, STATE FARM HAS THE TOOLS TO GET YOU TO A BETTER STATE.

PROUD SPONSOR OF "THE WOODWRIGHT'S SHOP."

CAPTIONING MADE POSSIBLE BY FRIENDS OF NCI HEY, HELLO AGAIN.

WELCOME BACK TO "THE WOODWRIGHT'S SHOP."

I'M ROY UNDERHILL.

DO YOU KNOW WHAT IT'S ALL ABOUT?

IT'S ALL ABOUT BOXES, BOXES.

IF YOU'RE DOINCARPENTRY, WHAT IS A HOUSE BUT A GREAT BIG BOX?

AND IF YOU'RE DOING JOINERY, WHAT IS JOINERY BUT A LITTLE TEENY BOX?

AND THAT'S WHAT WE'RE GONNA DO TODAY, AND WE'RE GONNA DO A LITTLE TEENY BOX.

NOW, THIS IS MY BOX OF 11 GROOVES.

THAT'S WHAT I CALL IT.

MY STUDENTS CALL IT "ROY'S BOX FROM H-E-DOUBLE HOCKEY STICK," BECAUSE IT IS A CHALLENGING BOX.

LOOK INSIDE.

IT'S GOT THE--NOT THAT.

BUT THE WONDERFUL LITTLE LIP ON THE INSIDE TO HOLD IT.

WE DO A GROOVE FOR THAT.

BUT YOU SEE, WHAT REALLY MAKES IT CHALLENGING IS THIS RIGHT HERE.

BECAUSE SEE HOW THE CORNER IS HELD WITH A SPLINE?

IT'S A MITER JOINT, BUT MITER IS NOT STRONG ENOUGH.

WE HAVE A CROSS-GRAIN SPLINE SPANNING THE GROOVE ACROSS THE GRAIN LIKE THAT.

A LITTLE CROSS-GRAIN SPLINE.

THAT'S WHAT MAKES IT CHALLENGING.

BUT AGAIN, THE BOX OF 11 GROOVES.

THE BEST WAY TO UNDERSTAND IT IS TO GO AHEAD AND MAKE ONE.

ALL RIGHT.

SO WE'RE GONNA GO AHEAD AND MAKE THE BOX OF 11 GROOVES, STARTING WITH THE FIRST 3 GROOVES.

ALL RIGHT.

SO I'VE GOT A 24-INCH PIECE OF OAK DOWN HERE.

IT'S A HALF-INCH THICK.

AND IN FACT, LOOK HERE.

HERE'S A HALF-INCH THICK BOX THAT INSPIRED THESE KIND OF BOXES.

THIS IS THE BOX FOR THE PLANE I'M GONNA USE.

IT'S AN OLD STANLEY 45 BOX.

AND THAT'S ONE OF THESE.

THIS IS A STANLEY 45.

IT HAS ALL THESE CUTTERS AND STUFF LIKE THAT.

AND I'M GOING TO USE 3 OF THEM JUST SET UP WITH DIFFERENT CUTTERS JUST TO SAVE TIME.

A LITTLE OAK BOX HERE.

SO WE'RE GONNA START WITH THIS ONE.

THIS ONE HAS BASICALLY DOWN TO A SINGLE SKATE.

THAT'S THIS LITTLE THING HERE.

THERE'S TWO SKATES ON A 45.

WE'VE TAKEN OFF ONE.

GOT THE DEPTH STOP SET AT AN EIGHTH OF AN INCH.

GOT AN EIGHTH OF AN INCH IRON IN THERE.

AND WE'RE AN EIGHTH OF AN INCH IN FROM THE FENCE.

SO HERE WE GO.

WE'LL GET DOWN HERE AND JUST START PLOWING.

THAT'S WHAT WE'RE DOING.

THIS IS A PLOW PLANE.

THAT'S WHAT THE 45 IS.

AND THIS ONE'S PLOWING A LITTLE BIT SCANT, I TELL YOU.

ALL RIGHT.

BUT WE'LL GET IT.

FORTUNATELY, UH... AND WHAT I MEAN BY THAT IS IT'S NOT TAKING AS DEEP A CUT AS I WOULD LIKE.

ALL RIGHT.

BUT WE'LL GET IT DOWN.

THERE WE GO.

AND IT WILL CUT UNTIL IT BOTTOMS OUT, AND YOU'LL HEAR NO CUTTING.

YOU HEAR?

NO CUTTING.

THAT HIGH SOUND OF CUTTING IS GONE.

THAT MEANS WE'VE GOT A GROOVE THERE.

THAT MEANS THE LITTLE DEPTH STOP HERE HAS ENGAGED.

SO NOW WE'LL TURN IT AROUND.

SO THERE'S GROOVE NUMBER ONE.

HERE WE GO TO GROOVE NUMBER TWO.

LET ME GET THIS ON THE BENCH AND TIGHTEN HER UP, AND TRY AND HAVE IT SO... WELL, ACTUALLY I'M A LITTLE BIT FARTHER OUT THAN I'D WANT TO BE, BUT IT'LL BE OK. USUALLY YOU DON'T WANT TO HAVE THE AREA THAT YOU'RE PLANING UNSUPPORTED.

SEE, I'M KIND OF PLANING OUT OVER THE AIR.

AND NORMALLY WE'D WANT TO HAVE THAT...UH...

HAVE BENCH UNDERNEATH IT.

SO WE'D WANT PLANE, IRON, WOOD, AND THEN BENCH, AND I HAVE PLANE, IRON, WOOD, AND...HA HA HA!

INFINITY DOWN BELOW.

NEVERTHELESS, THERE'S OUR SECOND GROOVE.

OK.

SO WE'VE GOT TWO GROOVES.

NOW WE'RE GONNA DO THE THIRD GROOVE A LITTLE WIDER.

HERE WE'VE GOT A DIFFERENT IRON, AND THAT'S WHAT WE CALL THESE CUTTERS.

THESE ARE THE IRONS.

THERE'S THE IRON IN HERE.

YOU SEE THE DEPTH STOPS ON EITHER SIDE.

THERE'S ONE, AND THERE'S THE OTHER ONE.

I PUT ON, EXTRA TO THAT STOP, AN EXTRA SKATE AND THIS WIDER IRON.

THIS IS GOING TO DO THIS GROOVE DOWN THE MIDDLE.

AND THIS'LL MAKE SENSE AS WE GO ALONG HERE.

AND I'VE GOT THAT SECOND DEPTH STOP ON THERE, BECAUSE WE MUST BE VERY CAREFUL NOT TO ROCK OVER.

ON A BROAD...

GROOVE LIKE THIS, IT'S EASY TO HAVE ONE EDGE OF IT QUITE DEEP AND THE OTHER ONE SHALLOWER.

WHAT USUALLY HAPPENS IS THE END FACING OFF THE BENCH GETS DEEPER.

ALL RIGHT.

SO...IN ORDER TO KEEP CUTTING... AND I'LL SHOW YOU.

WHAT FOLKS WILL DO IS ROCK THE PLANE OVER THIS WAY.

SO THEY ROCK OVER THIS WAY OFF THE BENCH, AND THAT CAUSES THAT UNEVEN CUT.

WITH THE TWO DEPTH STOPS ON THERE, WE KNOW THAT WHEN WE HEAR IT STOP CUTTING, IT MEANS TO STOP CUTTING.

OK.

SO THERE WE GO.

THERE'S OUR THIRD GROOVE.

SO WE'VE GOT 3 GROOVES.

NOW... WHAT IS THAT THIRD GROOVE ABOUT?

LET'S MAKE SOME SENSE OF THAT.

ALL RIGHT.

HERE IS A BOX THAT I CAN TAKE APART, AND IT HAS ALMOST ALL ITS PARTS.

THEY'RE GETTING SCATTERED HERE.

BUT IF I TAKE IT APART, YOU'LL SEE WHAT I'VE GOT INSIDE THERE.

THIS IS A BOX READY TO GO.

IT'S GOT THE SPLINES IN PLACE IN THE END GRAIN.

GOT THE TOP AND THE BOTTOM.

YOU CAN SEE.

SO THAT'S THE GROOVE FOR THE, UH...FOR THE TOP.

HERE'S THE GROOVE FOR THE BOTTOM DOWN HERE.

AND THIS MIDDLE ONE IS THE GROOVE FOR THE SPLINE.

SO AFTER WE SAW THE BOX APART ON THIS LINE RIGHT HERE, WE'LL PUT THIS LIP IN THAT'S CUSTOM-FITTED TO THAT, AND THAT WILL MAKE THAT WONDERFUL LITTLE LIP AROUND THE BOX.

SO WE PUT IT TOGETHER AND THEN SAW IT APART.

ALL RIGHT.

LET ME GET THIS OUT OF THE WAY, AND WE'LL MAKE THAT LIP.

I WILL GIVE YOU LIP NOW.

SO...HERE WE GO.

PUT THIS OVER HERE.

AND I'M GOING TO RESET THAT JUST RIGHT.

AND HERE.

BECAUSE WE'LL ACTUALLY USE THIS GROOVE TO CUT THE, UH... TO GET THE THICKNESS.

BECAUSE I DON'T HAVE ANY EIGHTH-INCH OAK.

SO I'M GONNA CUT IT DOWN USING THIS KNIFE HERE.

THIS IS A CUTTING GAUGE.

IT HAS A BLADE ON IT, A LITTLE BLADE INSTEAD OF A USUAL SCRATCHER CUTTER.

SO I'LL USE THAT KNIFE ACTUALLY DOWN THE LENGTH OF THE WOOD, WORKING RIGHT ON DOWN.

SO SLIDE IT ON DOWN THE WOOD LIKE THAT, TRYING TO CUT HALFWAY THROUGH FROM ONE SIDE, AND I'LL CUT HALFWAY THROUGH FROM THE OTHER.

NOW, THE PROBLEM IS IT GETS REALLY AWKWARD WHEN YOU GET UP AT THIS END TOWARDS THE SIDE.

I'M GONNA GO AND PUT THIS IN THE VISE DOWN HERE.

AND I'LL NEED THE VISE ANYWAY.

SO A CUTTING GAUGE TO CUT THE WIDTH OF OUR LIP ON THE INSIDE TO GO IN GROOVE NUMBER 3.

ALL RIGHT.

SO THAT'S IT.

THERE WE GO.

SO THAT HAS CUT THAT ONE.

WE'LL TURN IT AROUND AND CUT FROM THE OTHER SIDE.

AH.

IT'S JUST ABOUT TO HIT THE BENCH.

LIFT UP, UP, UP, UP.

ALL RIGHT.

AND RUN THAT DOWN, BECAUSE THAT KNIFE IS SHARP ENOUGH TO HURT YOU.

ALL RIGHT.

ON DOWN.

NOW HERE COMES THE FUN PART.

YOU TAKE THIS, TURN THIS OVER... AND SO WE'RE JUST TRYING TO CUT THIS DOWN TO SIZE TO FIT IN THAT GROOVE.

GET IT LIKE THAT, HOLD IT IN THE VISE, AND THEN POP IT ONE.

ALL RIGHT.

A LITTLE KARATE CHOP WILL GET IT OVER.

AND THEN WE HAVE TO PLANE OFF THAT ROUGH STUFF THERE.

SO IF WE'VE GOT THE WOOD OF THE RIGHT THICKNESS, WE CAN DO IT.

YOU DON'T WANT TO PLANE DOWN TOO MUCH.

WANT TO JUST GET THAT ROUGHNESS OFF.

AND I MAY HAVE TO COME BACK AND PLANE, BECAUSE THIS HAS GOT TO FIT WELL INSIDE THAT GROOVE.

ALL RIGHT.

LET'S GO AHEAD AND DO THAT.

THAT GOES RIGHT HERE.

AH, IT JUST DOESN'T WANT TO FIT.

I HATE THIS BECAUSE I HAVE TO KEEP PLANING IT OVER AND OVER.

LET ME SEE IF I'VE GOT ANOTHER ONE HERE.

OK.

UH.

I DON'T WANT TO DO THAT.

I'M GONNA TAKE THIS ONE HERE AND PUT IT IN THERE AND SHOW YOU THAT WAY, BECAUSE IT IS SO TEDIOUS TO GET THIS THING DOWN.

YOU HAVE TO STOP EXACTLY WHEN YOU HIT THE SURFACE OF THE OTHER WOOD.

SO WE WORK THIS DOWN PLANING.

TAKE THAT PIECE THAT WE CUT OFF, AND THEN JUST PLANE IT DOWN UNTIL WE ARE JUST FLUSH WITH THE SURFACE, AND THAT WILL GIVE US THIS LIP THAT'S GOING TO GO ON THE INSIDE.

SO IT'S GOT TO BE DEAD FLUSH.

ALL RIGHT?

SO DEAD FLUSH NOW.

IN FACT, THAT LOOKS PRETTY GOOD.

ALL RIGHT.

SO LET'S USE THIS ONE.

I JUST GRABBED ANOTHER ONE AND STUCK IT IN THERE AND SKIPPED THAT STEP, BUT I DO HAVE A STEP I CANNOT SKIP.

I'VE GOT TO MAKE THIS TIGHT.

AND I SAY BECAUSE, UH...

IT IS NOT THE ONE EXACTLY FOR THIS, I'VE GOT TO PUT A LITTLE STICK IN THERE AND SEE IF I CAN SPRING THIS IN.

THERE WE GO.

OK.

I'M GONNA SPRING IT IN WITH ALL MY MIGHT, BECAUSE I WANT THAT TO STAY TIGHT IN THERE.

SO THAT LIP NEEDS TO STAY TIGHT DURING THIS NEXT STEP, WHICH IS CUTTING.

SO WE'RE GONNA CUT THE 4 SIDES.

THESE ARE THE SIDES OF THE BOX.

WE GOT THE GROOVE FOR THE TOP, GROOVE IN THE MIDDLE, AND WE'VE GOT THE SPLINE READY.

SO NOW WE CAN START CUTTING.

AND I'M GONNA USE THIS MITER BOX, AND YOU VERY OFTEN TRUST THESE... [BLOWS] TO YOUR DETRIMENT.

IN OTHER WORDS, CHECK AND MAKE SURE.

YOU THINK, WELL, IT'S GONE INTO THE DETENT.

IT MUST BE AT 45.

I HEARD IT CLICK.

CHECK THE LITTLE GAUGE THERE, ALL RIGHT, AND SEE, BECAUSE ONE DEGREE OFF, AND IT'S NOT RIGHT.

SO HERE WE GO.

WE'VE ALWAYS GOT TO SAW FROM THE OUTSIDE.

SO THAT MEANS THAT LIP IS ON THE OTHER FACE.

THERE WE GO.

ALL RIGHT.

THAT IS A NICE SHARP SAW.

SO THAT'S CUT THAT PIECE OUT, AND WE'VE GOT A NICE MITER THERE, AND IT'S NOT JUST A MITER ON THE SIDES OF THE BOX, BUT IT'S ALSO ON THAT LIP THERE.

AND THAT'S WHY WE WANT IT TO STAY IN PLACE, BECAUSE WHEN YOU DO THE NEXT CUT, WE WANT IT TO REMAIN.

SO LET'S DO THAT.

I'M GONNA GO 4 1/2 INCHES.

4 1/4 INCHES DOWN.

AND THAT'S JUST THE SIZE THAT WILL MAKE THIS...

THE LID FIT IN THE SIZE STOCK I HAVE.

SO 4 1/4 INCHES.

AH...BUT...

DO I NEED TO MARK IT?

I NEED TO MARK IT FROM...

UH...FROM...

THIS SIDE.

OK.

SO THIS IS THE SIDE.

BECAUSE WHAT YOU'RE DOING IS FLIPPING EVERY TIME YOU DO THIS.

EVERY TIME YOU MEASURE THIS OVER, YOU'VE GOT TO FLIP IT ONE SIDE TO THE OTHER.

SO THERE WE GO.

4 1/4.

AND SO NOW, SEE, MY LONG SIDE IS GOING THE OTHER WAY, BECAUSE WE ALWAYS SAW FROM THE OUTSIDE, JUST LIKE WITH MOLDING, YOU KNOW, BECAUSE WHERE THE SAW EXITS, IT'S MUCH ROUGHER.

IT LEAVES A ROUGH EXIT WOUND.

SO WE WANT TO COME IN...

THERE WE GO.

WANT TO COME IN FROM THE OUTSIDE THERE.

AND THAT WILL LEAVE THE OUTSIDE NICE AND SMOOTH AND PUT THE ROUGH STUFF TO THE INSIDE.

AND YOU CAN SEE MY SPLINE I HEARD FALL OUT THERE IS PERFECTLY FITTED WITHIN THERE SO THAT WHEN WE PUT THE BOX BACK TOGETHER, THAT LITTLE LIP WILL BE INSIDE THERE.

THIS WILL MAKE SENSE AS WE GO ALONG.

SO NOW WE'RE GONNA, OF COURSE, CUT THIS OUT-- SHORT ONE, LONG ONE, SHORT ONE, LONG ONE, AND TRY AND KEEP THE GRAIN IN ORDER.

BUT LET'S GO AHEAD AND DO THAT NEXT STEP, WHICH IS THE CHALLENGING ONE.

THIS IS THE ONE WHERE WE CUT NOT WITH THE GRAIN, NOT ON THE END GRAIN REALLY, BUT OBLIQUELY TO THE GRAIN.

AND SO I'LL NEED TO GET ANOTHER PIECE.

THAT'S WHAT'S SO-- WELL, HERE, I'LL JUST USE THIS ONE.

THAT'S WHAT'S VERY NICE ABOUT MITERS.

UH...THEY'RE 45 DEGREES.

ISN'T IT?

YEAH.

THEY'RE 45.

SO TWO OF THEM ADD UP TO WHAT?

90.

SO WE CAN TAKE TWO 45's, PUSH THEM TOGETHER THERE, AND NOW WE HAVE A-- OOPS.

I LET IT SLIP.

A RIGHT ANGLE.

LET'S TRY THAT AND SEE IF I CAN GET THAT TO HOLD TIGHT, BECAUSE, BOY, DOES IT GOT TO HOLD TIGHT.

SO WE WANT 45 DEGREES.

I'M NOT THRILLED WITH THAT.

LET ME USE THIS ONE HERE.

OK.

I'M GOING TO GET RID OF THIS BIG ONE.

AND THE REASON FOR THAT IS, UH, JUST FOR US RIGHT NOW, I WANT TO BE ABLE TO... ALL RIGHT.

GONNA LINE THEM UP.

PUT THEM RIGHT HERE IN THE MIDDLE OF THE VISE, BECAUSE IF THERE'S ANY SLIPPING-- AND THAT'S ONE OF THE THINGS THAT GETS YOU-- THE WOOD WILL SLIP BECAUSE IT'S NOT HELD FULLY.

WE'VE GOT ALL KIND OF TROUBLE READY TO HAPPEN.

AND THIS IS WHAT KILLS THE STUDENTS HERE.

SO HERE WE ARE.

WE'VE GOT ANOTHER STANLEY 45 SET UP WITH ANOTHER 1/8-INCH IRON.

A LITTLE BIT DIFFERENT SETTING THERE.

THERE'S A DEPTH STOP.

SO THIS IS GOING TO CUT THE SPLINE GROOVE.

NOW, WHEN IT EXITS, AS YOU KNOW, ACROSS THE GRAIN, IT'S GOING TO LEAVE-- IT'S GOING TO TEAR OUT, IT'S GOING TO BUST OUT THE GRAIN ON THIS FAR END AT THE END OF THE STROKE BECAUSE IT'S CUTTING CROSS-GRAIN.

SO WHAT WE WILL DO IS CUT AHEAD OF TIME.

AHEAD OF THE IRON, WE WILL CUT RIGHT HERE.

THAT'S SOME-- THAT'S NICE TOUGH WOOD.

THIS MIGHT BE OK. AND RIGHT HERE, BECAUSE THIS IS VERY FRAGILE.

WE'RE CREATING A VERY LITTLE SHORT TRIANGLE OF END GRAIN THAT COULD EASILY BREAK OUT.

SO YOU CAN'T HAVE ANY SLIPPING ON YOUR FENCE.

IF THIS SLIPS BACK AND FORTH ON THE ROD, UH, TROUBLE.

ALL RIGHT.

SO LET'S SEE IF WE CAN DO IT.

LET'S SEE IF WE'VE GOT THAT CUT COMING THROUGH THERE.

AND THAT ROCKING OVER I WAS TALKING ABOUT BEFORE, YOU THINK IT WAS TROUBLE ON THE LONG GRAIN.

IT IS REAL TROUBLE HERE, BECAUSE THIS IS SO FRAGILE.

SO YOU DON'T GO TOO DEEP.

YOU'VE JUST GOT TO GET DEEP ENOUGH THAT THAT SPLINE IS GONNA GRAB.

AND LET'S SEE WHAT WE CAN DO.

I MEAN, IT'S JUST THE NATURE OF IT THAT SOMETIMES THE MAGIC WORKS.

YOU MUST GO TO THE FULL DEPTH.

THAT MEANS...UNTIL NOW.

YOU CAN HEAR IT'S NOT CUTTING ANYMORE.

ALL RIGHT.

AND WE HAVE CUT A NICE GROOVE ACROSS.

THAT'S GREAT.

OK.

SO WE'VE CUT NOW ONE OF THE SPLINE GROOVES, AND IT WORKED OK. THAT IS NOT TORN UP.

AND THE EXIT IS NOT TOO BAD.

SO NOW WE HAVE TO MAKE THE SPLINES THAT GO IN THOSE GROOVES.

AND IF WE LOOK AT IT HERE-- OK.

THERE'S THE MITER.

OH, NOW THAT ONE IS TORN UP.

BUT THERE'S THE MITER THERE.

AND YOU CAN SEE IT'S A NICE MITER, BUT IF YOU HAVE A SPLINE THAT'S TOO BIG AND BOTTOMS OUT, IT'LL PUSH THE MITER APART, OR IF THEY'RE OFFSET BECAUSE THE PLANE SLIPPED, IT'S JUST NOT GOING TO WORK.

SO EVERYTHING'S GOT TO BE VERY, VERY PRECISE.

SO WE'RE GOING TO WORK ON NOW MAKING VERY PRECISE LITTLE SPLINES TO GO IN THAT GROOVE THAT WE'VE CUT IN EACH OF THE MITERS.

ALL RIGHT.

SO THAT AGAIN TAKES US BACK TO THE MITER BOX.

I HAVE SET A GAUGE ALREADY TO THE, UH... WHAT I THINK IS GOING TO BE THE RIGHT, UH... HOW SHALL I SAY?

THE RIGHT, UH...

LENGTH, WHATEVER.

BECAUSE, REMEMBER, IT'S GOING TO BE THE END GRAIN, THE CROSS GRAIN, THE LONG GRAIN, THE GRAIN THAT DOES THE STRENGTH OF THIS PIECE.

SO WE'VE GOT TO CUT IT OFF JUST RIGHT.

NOW, I HOPE I'VE GOT A GOOD SQUARE CUT THERE.

THAT LOOKS LIKE THE ORIGINAL.

I CAN'T.

I HAVE TO CUT THIS TWICE.

ALL RIGHT.

AH, LOOK RIGHT HERE.

HERE'S WHAT HAPPENED.

DO YOU SEE WHAT'S HAPPENED?

I SWUNG THIS AROUND TO THE DETENT, THINKING I HAD IT JUST RIGHT.

I AM ONE DEGREE OFF RIGHT THERE.

AND THAT IS ENOUGH TO DO IT.

SO THIS WHOLE THING HAS GOT TO COME UP AND COME OVER TO THAT ZERO POINT.

I WAS JUST WORKING TOO FAST.

GOT TO RECUT THAT SHOULDER.

AND IT'S ERRORS LIKE THAT JUST CREEPING--[BLOWS] ALL THE WAY THROUGH THIS THING THAT'LL THROW YOU.

YOU'RE SAYING, "WHY IS THIS NOT WORKING?"

WELL, IT'S BECAUSE OF THAT ONE DEGREE OFF.

AND THERE IT WAS.

ALL RIGHT.

SO NOW WE'VE GOT A GOOD SQUARE.

IN OTHER WORDS, WE'RE SQUARE NOW TO THIS MITER BOX.

WE CAN'T JUST TRUST THE FACTORY-CUT EDGE.

WE'VE GOT TO CUT A FRESH ONE AND THEN CUT PARALLEL TO THAT IN ORDER TO MAKE SURE WE HAVE A PARALLEL CUT.

SO NOW I'LL COME DOWN ON THAT.

LET ME SEE IF I CAN GET RIGHT IN THERE.

WHEW.

AND THIS SHOULD GIVE US A PARALLEL, UH...SLICE.

THERE WE GO.

ALL RIGHT.

NOW, THIS IS A QUARTER-INCH THICK.

IT'S GOT TO GO DOWN TO AN EIGHTH-INCH THICK.

AND TO DO THAT--THAT'S A PRETTY FRAGILE THING TO PLANE, BUT WE'VE GOT A LITTLE HOLDER FOR IT MADE UP.

SO THIS IS WHAT'S GOING TO HELP US GET THE PRECISION WE NEED.

IT'S A LITTLE BLOCK OF OAK WITH A GROOVE CUT IN IT THAT THIS WILL FIT DOWN INTO.

AND IT WILL HOLD, IT WILL CRADLE THE WOOD WHILE WE-- I'M GONNA HAVE TO REACH BACK AND GET MY PLANE.

AH!

HERE WE GO.

ALL RIGHT.

AND IT WILL CRADLE THE WOOD WHILE WE PLANE OFF THE TOP UNTIL WE GO LEVEL WITH THAT OAK PIECE.

AND THEN WE'LL KNOW THAT IT'S AN EIGHTH OF AN INCH THICK.

SO I'LL TRY AND HOLD THE PLANE SLIGHTLY ASKEW.

AND THAT'S A LOT OF CUT THERE COMING OFF, BUT I LIKE THIS LONGER-BEDDED PLANE BECAUSE IT HOLDS IT DOWN.

I'LL GO TO THE BLOCK PLANE AS I GET CLOSER.

OK. NOW I'M CLOSE ENOUGH TO GO TO THE BLOCK PLANE.

I LIKE THAT BEING HELD.

ALL RIGHT.

SO THERE WE ARE.

NOW WHAT I DO IS TURN IT AROUND BECAUSE SOMETIMES YOU HAVE A LITTLE BIT OF SLOPE IN THERE.

AND I USED VERY CAREFUL CUTTING TO MAKE THAT JUST AN EIGHTH OF AN INCH DEEP.

SO THIS SHOULD NOW BE AN EIGHTH OF AN INCH THICK.

SO IF WE FEEL IT IN HERE, IT SHOULD--OH, LOOK AT THAT.

ALL RIGHT.

JUST THIS.

JUST FINE.

SO THAT'S A GOOD GLUE FIT.

NOW, THE PROBLEM IS, IS IT TOO LONG?

WELL, WE'VE GOT ANOTHER PARALLEL GROOVE RIGHT HERE WE CAN DROP THIS INTO.

THERE WE GO.

COMES RIGHT UP TO THE EDGE.

AND NOW PLANE THE EDGE GRAIN HERE, THE END GRAIN.

AND THIS HOLDING IT IN THE CRADLE MAKES SURE THAT IT'S NOT GOING TO CRACK, BECAUSE YOU CAN IMAGINE THAT'S FRAGILE.

BECAUSE THE WHOLE TRICK WITH THIS IS-- AND LET'S SEE IF WE'VE GOT ONE THAT'LL--WILL THIS FIT?

IT MIGHT.

LET'S SEE.

THIS WILL GO IN HERE AND-- OH, OK. THAT'S FROM A SMALLER ONE.

ALL RIGHT.

I'VE GOT DIFFERENT BOXES HERE.

THIS WILL GO IN HERE AND THEN FIT IN THE RECIPROCAL ONE, AND WE KNOW IT WILL SPAN THE JOINT WITHOUT HOLDING IT APART.

ALL RIGHT.

NOW WE'RE GONNA MAKE THE TOP.

SO WE TAKE THE BOX, PUT IT TOGETHER.

IT DOESN'T HAVE THE TOP IN IT YET.

BUT WE'VE GOT IT TOGETHER WITH THE SPLINES.

TIGHTEN IT UP, AND MAKE SURE THAT WE HAVE EVERYTHING FITTED AS IT SHOULD BE.

OK. A LOT OF BOX PARTS FLOATING AROUND HERE.

WE THEN MEASURE THE DISTANCE FROM INSIDE THE GROOVE TO INSIDE THE GROOVE AND THEN CUT A LITTLE SHOULDER.

LOOK AT THE RABBET HERE.

THIS IS WHAT WE DO.

THIS IS WHAT HOLDS THE LID IN PLACE.

IT'S THIS LITTLE LIP RIGHT THERE.

YOU SEE THAT?

SO WE TAKE THE QUARTER-INCH BOTTOM, AND, UH...

PLANE OFF PART OF IT.

WELL, THAT'S AGAIN A TOUGH THING TO HOLD.

BUT WE'VE GOT ANOTHER WAY TO DO IT.

UH...THIS IS THE TRICK FOR HOLDING SHORT PIECES, BECAUSE IN THE VISE, THE END VISE DOWN THERE, IT JUST DOESN'T GET-- THE JAWS DON'T GET CLOSE ENOUGH.

SO HERE I'VE GOT, UH... A LITTLE, UH...HANDSCREW.

AND TIGHTENING IT UP WHILE HOLDING IT IN THE VISE WILL HOLD THIS JUST RIGHT.

SO NOW I'VE GOT THAT HELD.

SO WE CAN USE THIS PLANE ON IT.

THIS IS A MOVING FILLISTER PLANE.

IT'S JUST REALLY A WONDERFUL PLANE.

AGAIN YOU CAN SEE THE NICKER THAT PROCEEDS THE CUTTER.

HERE'S THE DEPTH STOP BACK HERE, AND HERE'S THE FENCE, AND WATCH WHAT IT WILL DO.

VERY CAREFULLY WE PULL BACK ON THE FIRST STROKE TO SEVER THE GRAIN, AND THEN GO ACROSS, AND IT WILL GO DOWN UNTIL THE DEPTH STOP STOPS THE CUTTING.

ALL RIGHT.

AND THAT'S IT.

WE ARE DOWN.

AND NOW THAT WILL FIT IN THE GROOVE, THAT GROOVE NUMBER ONE THAT WE PLOWED THERE TO MAKE THE BOTTOM OR THE TOP.

SO WE ARE GOOD TO GO WITH THAT.

WE DO THE END GRAIN FIRST, AS I'VE DONE HERE, AND THEN WE COULD TAKE IT DOWN TO THE END DOGS AND PLANE THIS SHOULDER.

WE DO THAT LAST BECAUSE YOU CAN SEE RIGHT HERE HOW THIS SPLIT OFF.

THAT WAS A FUNCTION OF PLANING ACROSS THE GRAIN.

SO USUALLY WHEN YOU DO THIS, CUT ACROSS THE GRAIN FIRST, THEN DO YOUR LONG-GRAIN CUTS THAT WAY.

ALL RIGHT.

SO THERE'S OUR TOP.

WE DO OUR BOTTOM.

WHAT ARE WE GONNA DO NEXT?

WE GLUE IT UP.

OK.

SO TAKE THE BOX, PUT THE... MAKE SURE THE LIPS ARE NOT IN THERE.

UH, PUT IT TOGETHER.

GET THE GLUE ON IT.

AND THAT IS A REAL FIRE DRILL, GETTING THAT DONE.

EVERYBODY RACING AROUND, GETTING THE GLUE.

AND I USE THESE GLUE BLOCKS TO HOLD IT.

PUT THESE AROUND LITTLE CORNERS.

PUT A ROPE AROUND ALL 4 OF THE BLOCKS... LIKE THAT, AND THEN PUT A TOGGLE IN THERE TO START TWISTING IT.

ALL RIGHT, AND THAT'S GONNA ALLOW YOU TO SQUEEZE IN THE BOX FROM ALL 4 SIDES.

SO THAT'S HOW YOU DO IT.

YOU TWIST THIS TOGGLE AND THE ROPES, AND THAT WILL SQUEEZE IT TOGETHER.

NOW IT'S GLUED TOGETHER.

WE'VE GOT A BOX.

WE CAN'T GET INTO IT.

HOW ARE WE GONNA GET INTO IT?

WE'VE GOT TO SAW IT APART.

ALL RIGHT.

SO HERE'S THE FUN PART.

ACTUALLY, I THINK THE PLANING IS THE GREAT FUN, BUT THIS IS PRETTY COOL, TOO.

YOU'VE GOT TO BE CAREFUL, BECAUSE YOU'VE DONE ALL THIS WORK, AND HERE'S A CHANCE TO MESS IT UP BY SQUEEZING TOO HARD, BY CRACKING IT.

UH...THERE ARE INFINITE WAYS WE CAN CAUSE MISCHIEF TO OUR BOX.

BUT NEVERTHELESS, WE'LL PUT IT IN DIAGONALLY.

LIKE CUTTING A TENON.

AND TAKE A DECENT TENON SAW HERE AND RIP IT OPEN.

NOW, ONE THING--SEE, I KNOW WHERE TO SAW.

I'M 2/3 OF THE WAY UP THAT INNER GROOVE THERE.

WHY?

HOW DO I KNOW THAT?

BECAUSE I THOUGHT TO MARK IT BEFORE I GLUED THE BOX TOGETHER.

THAT WAS A VERY HELPFUL THING TO HAVE DONE.

ALL RIGHT.

SO NOW I'M INTERSECTING THAT ONE HERE, AND I'VE ALREADY SAWN ONE SIDE.

SO LET'S SEE IF I CAN BRING THIS SAW DOWN THAT LINE AND CONNECT THE TWO.

ALL RIGHT.

AND OH, IT LOOKS LIKE I'M OFF A LITTLE BIT.

SO WHAT HAPPENS?

BIG DEAL.

YOUR BOX GETS A LITTLE BIT SHORTER.

SO THAT'S IT.

NOW WE CAN TAKE... HA HA HA...THE BOX, AND IT SHOULD COME OPEN.

THERE WE ARE.

ALL RIGHT.

SO NOW WE HAVE THOSE LIPS AROUND HERE.

NOW, THIS IS A BOX WHERE THE SPLINES, UH... ACTUALLY, I'M SORRY.

THIS SECOND GROOVE-- ONE OF THE STUDENTS PLOWED IT A LITTLE DEEP.

LET'S LOOK AT ONE THAT HAS, I THINK... YEAH, THIS ONE HERE.

ALL RIGHT.

THIS ONE HAS THE SPLINES READY TO GO.

SO WE SAW THE BOX OPEN, AND WE TAKE THE LITTLE LIPS THAT WE HAD BEFORE.

WE PUT THEM ASIDE.

WE HAVEN'T LOST THEM.

AND STICK THEM HERE LIKE THAT.

OK. AND WE'RE GLUING IT.

GLUING IT ALL THE WAY AROUND THAT LIP THERE.

AND PUTTING IT IN.

WE ASSEMBLE THAT.

AND THIS GOES RIGHT LIKE THAT.

NOW, BECAUSE THESE LIPS WERE MADE TO FIT THE FULL WIDTH OF THE GROOVE, AND NOW WE'VE TAKEN OUT ONE SAW KERF--THERE YOU GO.

THERE IS OUR LIP AROUND THE INSIDE OF THE BOX.

WE HAVE TO TAKE THE BLOCK PLANE, AND WHERE HAVE I GOT IT?

RIGHT HERE.

THERE WE ARE.

AND PLANE THIS DOWN ONCE THAT'S GLUED INTO PLACE.

PLANE IT DOWN SO THE LID WILL FIT DOWN IN THERE.

AND OF COURSE, YOU PLANE THIS SURFACE AND THIS SURFACE RIGHT HERE ALL THE WAY AROUND UNDER THE LID.

NOW, THIS IS A GREAT BOX FOR VENEERING, BUT I JUST LEAVE IT LIKE IT IS, BECAUSE LOOK AT THAT.

WHEN YOU GET TO SAW INTO THOSE WONDERFUL LITTLE CORNERS THERE, YOU CAN SEE THAT WONDERFUL SPLINE DOWN INSIDE THERE, AND JUST MAKING IT SMOOTH IS JUST THE NICEST THING OF ALL.

SO ANYWAY, THAT PUTS A LID ON OUR 11-GROOVE BOX.

IT'S ALL RIGHT?

IT'S ALL RIGHT.

ALL RIGHT.

WELL, THAT'S IT.

IT'S A NEAT THING.

I DON'T KNOW WHY THEY HAD SO MUCH TROUBLE WITH IT.

IN ANY CASE, WE'LL SEE YOU NEXT TIME HERE IN "THE WOODWRIGHT'S SHOP. "

THIS IS ROY UNDERHILL.

SO LONG.

HA HA HA.

LEARN MORE ABOUT "THE WOODWRIGHT'S SHOP" AND TRADITIONAL WOODWORKING ON OUR WEBSITE.

YOU CAN FIND US ONLINE AT pbs.org.

CAPTIONING MADE POSSIBLE BY FRIENDS OF NCI MAJOR FUNDING FOR "THE WOODWRIGHT'S SHOP" IS PROVIDED BY... [THUNDER] [CAR ALARM BLARING] WHEN THE UNEXPECTED HAPPENS, STATE FARM HAS THE TOOLS TO GET YOU TO A BETTER STATE.

PROUD SPONSOR OF "THE WOODWRIGHT'S SHOP."

ROY UNDERHILL IS THE AUTHOR OF "THE WOODWRIGHT'S GUIDE: WORKING WOOD WITH WEDGE AND EDGE," AS WELL AS OTHER BOOKS ON TRADITIONAL WOODWORKING, ALL PUBLISHED BY THE UNIVERSITY OF NORTH CAROLINA PRESS AND AVAILABLE IN BOOKSTORES AND LIBRARIES.