School of Arts (NSW)
TECH107 Design Issues in Timber
OPERATION SHEET
Student Name: Isabella Paparo
Date: 25th October 2016
Component Name: Storage Box
Material / Size:
OPERATIO
NNUMBER
NAME OF
OPERATION
MACH TOOL
10
Mark out material
-Pencil
-Rule
-Tri Square
20
Cut material
-Bench Hook
30
Sand material to size
-Disk Sander
40
Mark out rebate
-Pencil
-Rule
-Tri Square
-Marking Gauge
50
Cut rebate
-Bench Hook
-Table Vice
-Wooden Mallet
CUTTING TOOL
-Tennon Saw
-Tennon Saw
-Bevelled Edge
Chisel
SPEED
FEED
DEPTH OF
CUT (mm)
Hand
Hand
1420 RPM
Hand
Holding the piece of timber firmly against the guard, slowly
pushing pressure on the back of the timber, move the timber
along with the guard in a sideways motion until at desired length
Hand
Set the marking gauge to the appropriate thickness (6 mm) to
create the thickness of the rebate that is needed to be cut and
run the gauge around the edges of the timber. On the top face,
measure 12 mm from the side where the rebate is to be cut.
Hand
2 6 x 68 x
6
-12
-6
REMARKS
With the square and pencil, ensure that timber is square. Using
the rule, square and pencil mark out the appropriate length of
material. Label each piece with what part and its dimensions
leaving a 5 mm gap between each piece for it to be cut.
Using the bench hook secured in the vice, hold the timber
against the hook with non-dominate hand, using the dominate
hand, hold the Tennon saw with a pistol grip slowly cutting the
timber.
With the timber securely held in place with the bench hook, using
the Tennon saw, carefully saw down to the marking gauge line.
Once the cut has been made, place the timber piece in the table
vice, using a wooden mallet and chisel remove the excess waste
from the timber creating the rebate.
60
Mark out Finger
-Pencil
-Rule
-Tri Square
Hand
70
Cut finger
-Bench Hook
-Wooden Mallet
-Table Vice
-Quick Release Clamp
80
Plane rebate for base
-Table Vice
-Rule
90
Mark out divider
placement
-Pencil
-Rule
-Tri Square
100
Cut out divider
placement joint
-Bench Hook
-Wooden Mallet
-Tennon Saw
-Bevelled Edge
Chisel
Hand
3 12 x 22
x 12
With the timber being placed securely in the table vice, cut along
the line where the finger is to be removed. Take the timber out
of the vice and secure it to the bench hook with a quick release
clamp, using a chisel and wooden mallet, remove any excess
waste material from the timber.
-Rebate Plane
Hand
-6 x 6 x
entire inner
base of the
carcass
By securing the timber in the table vice and ensuring that the
rebate plane is set to the correct length, stroke the plane
alongside the inner edge of the base of the timber creating the
rebate. Make sure the plane does not damage the edges of the
timber.
Hand
Using the tri square and rule mark our where he placement of
the divider is to be. Once marked out on one side timber piece
carefully transfer the same measurements and placements of
the divider to the other side timber piece to make sure that it is
straight once glued together.
Hand
-12 x 58 x 5
Using the bevelled edged chisel, carefully place it on the
outsides of the marked area using the wooden mallet to hit the
top of the chisel causing a slight cut in the timber. Then using a
mortising chisel remove the excess waste material carefully with
slight pressure being placed on the back of the chisel. Be careful
to not chisel too deep into the timber and ensure that where the
stopped housing joint is to end is straight
105
Mark out divider shape
-Pencil
-Rule
-Tri Square
Hand
Transfer the measurements of the stopped housing joint to the
top of the divider to ensure that it will be flush with the top of the
box
110
Cut divider
-Table Vice
-Wooden Mallet
Hand
2 5 x 10 x
12
120
Dry cramp
-Sash Clamp
-Scrap Wood
-Tri Square
Hand
Assemble the carcase with the base and divider in a set of sash
clamps with scrap wood around it so the box does not get
damaged, using the tri square check that everything is square
before the glue is anywhere on the project
130
Roughly Sand
-120,180 Sandpaper
-Cork Block
Hand
Roughly sand each piece of timber using sandpaper wrapped
around a cork block and going with the grain of the timber.
-Bevelled Edge
Chisel
-Mortising Chisel
-Tennon Saw
-Bevelled Edge
Chisel
Using the tri square and rule, carefully measure three equal
distances (22 mm) to create the fingers. Ensure that all lines are
straight to create the perfect finger once cut.
Place the timber piece in the table vice and saw alongside the
marked line. Using the Chisel and wooden mallet, remove any
excess waste material
140
Glue carcass, divider
and base
-Sash Clamps
-PVA Glue
-Scrap Wood
-Tri Square
-Wet Cloth
Hand
Using PVA glue place glue in each of the joints and the base of
the carcass. Once put together place in sash clamps to glue
together. Ensure that there is scrap wood where the sash clamps
touches the project checking that it is square using the tri
square. Once the sash clamps have been tightened check for
squareness again and using the wet cloth clean any glue that
may have leaked off the job.
145
Mark out lid stopper
position
-Tri Square
-Rule
-Pencil
Hand
In diagonal corners, mark out where the corner of the box will
end (12 mm in from each side) using the tri square ensure that
each is straight and square
150
Attach lid stoppers
-PVA Glue
-Warrington Hammer
-10 mm Nails
-Wet Cloth
-Masking tape
Hand
Place a small amount of PVA glue underneath the lid stopper
and put into place, place a small amount of masking tape over
the stopper to hold it in place whilst using the Warrington
hammer to hammer in the nails. Once two outside nails have
been placed, remove the tape, hammer in a last nail in the
centre and clean any glue that may have escaped from the base.
160
Sand everything again
-180,400 Sandpaper
-Cork Block
Hand
Once everything has been glued together, sand the job using
sandpaper wrapped around a cork block going with the direction
of the grain
170
Oil project
-Clean Rag
-Danish Oil
Hand
Using a clean cloth and Danish oil, oil over the job ensuring that
there are no streak marks and it is an even coat of oil
180
Sand project
-400 Sandpaper
-Cork Block
Hand
After the oil has completely dried, using a cork block covered in
sandpaper, lightly sand the box to create a nice smooth feel.
190
Oil project
-Clean Rag
-Danish Oil
Hand
Again using a clean cloth and Danish oil, oil over the job
ensuring that there are no streak marks and it is an even coat of
oil
General Comments: Overall I am happy with what I had produced for the storage box for the time period I had to construct it in. The finger joints were done
well but the rebate joints could have been finished a little neater. I would have much preferred to use some form of butt hinges to attach the lid but I am happy
with how the wooden lid stoppers had turned out. If I had to construct the box again I would have allowed myself more time for oiling the project once
construction was finished.
