Pew Box Project - Part 1

Work has finally begun on getting the actual boxes produced. To start with I created a cut list detailing dimensions and number of pieces needed to build 28 boxes. The first order of business was getting the cove cut on the end pieces. After scratching my head trying to come up with an efficient and cost effective way to cut the coves I decided to use my table saw. This beats the expense of buying a new router bit and the time of searching for said bit since there seems to be a lack of them locally. The cove is approximately 1 inch wide by 1/4 deep. Two passes of 1/8 inch each were made to achieve the final depth. A third pass was run as a cleanup pass to minimize sanding later. To set up the jig on the table saw I used two strips of Poplar as a guide clamped at the appropriate angle and width.

Click on the photos below to see how the saw was set up for the cove cut.