I needed to tidy up my battery repair gear so i made a box to keep everything in I found two clean Euro pallets 1200 x 800 being tossed so I "rescued them" If you wondered about using pallets look for these details to guide you. I dismantled them and managed to reclaim about 50% The particle board blocks and bases were sawn off and dumped leaving enough to keep me busy. Set to work Jointing them. and just about all were usable I decided to thickness them to about 16 mm This provided enough stock for the Frame and base The remaining top pieces I will use for the Lid and internals . The frame concept The two with knots will be the ends and test jig for profiling I hadn't used my Gifkins Dovetail jig for ages so it got a workout First up a test fit piece was made
used for the profiling and biscuit alignments Happy with that the frame was dovetailed. Biscuited two pieces together for the base Then started on the lid At first I thought about a cross section top decided it would be all too much work and decided to think again I had three pieces suitable so I went with them Less process and it should work OK I though I would have less cupping and stabilising defects that way. After making a fitting I didn't have enough material to saw in a raised panel so it stayed flat Glued up the frame and base, then saw raised profiled the test piece at 5 deg I found I would lose about 50% of my dovetail joint if I stayed at 5 deg so I reduced it to 2.5 Deg and a 45 mm height Sanded and trued everything on the frame and set to work making mock raised panels set up a sacrificial fence to maintain alignment the raw finish final concept Lotta fun and skill building too.
