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
L lam intriguedwiththisproject.Itnotonlyholdsand
protectsthe chisels,it's alsoa working displaybox.
The fact that we used this box for chisels doesn't
mean that it wouldn't work equally well for a set of
knives, or by removing the dMders, it could hold a
specialbook or housethe family album.
ENDGRATN. Since the toleranceson this case are
verytight,I hadto paycloseattentionto the movement
of the wood asit expandsandcontracts(with seasonal
changesin humidity). To prevent problemswith the
wood splitting,the grain of all the piecesshouldrun in
the samedirection.
While it may seemlike alot of extra work to dealwith
all of the endgrain pieces,the result is well worth it. All
of the grain in the case runs in the same direction,
almostasifthecasewerehollowedoutof a singlepiece
of wood.By doing this, any movementin the casethat
Woodsmith
should occur will not open any of the joints or cause
cracksto develop.
roIrqBnv.While thejoinery in this projectis not com-
plicated, precise fits are very important. For most
pieces,I recommendthey be cut oversized,and then
trimmed to fit.
woon. When choosingwood for the case,try to use
hardwoodsthat havebeen kiln dried. No matter how
carefully the caseis constructed,using wood with a
high moisturecontentwill causeproblems.
I built this caseout of walnut. The handles on the
chisels are light colored and the dark background
makesthem standout. Walnut is stableand relatively
easyto workwith.
FINISH.After completingthe case,the interior and
the exterior were finished with three coats of hand-
rubbed tung oil. If you feel you need a more durable ,A\
finish, polyurethanewill offer more protection.
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-
mining thewidth of the end blocks (A). The
width dependson three things: the width of
your widest chisel, the number of chisels,
and the thicknessof the tray dividers.
DETERMINING TIIE WIIIH. MeasuTethe
widestpartofyourlargestchisel,addVsrrfor
clearance,and this will be the width of each
bay section.(Thelargestchiselin my set is
178rrwide, soeachtray sectionis 1Vtrrwide.)
Once you know the size of each section,
you can multiply that figure times the num-
ber of chiselsyou have.(I havesix chiselsso a blank l0rrwideby 8rrlong,seeFig. 1.
6xl774tt=7Vzt.) When the glue is dry, trim both endsand
Also, determinethe total thicknessof the then cut off a 6rllong piece,leaving a 17arl
tray dividers. (SinceI used sevenV+rr-thick piece,see Step 1. (Savethe short piece for
dividers the total thickness of all of the later use.) Now, rip the 6'r-longpieceto the
dividersis 13l+rr.) finishedwidth for your end blocks (9Vlrr).
Now, add the total width of the tray sec- To get the thicknessneededfor the end
tions (7/zrr) and the total thickness of the blocks,cut the 6rLlongpiecesin half andglue
dividers (13l+")to get the total width (9V+'r) these two pieces together face-to-faceto
of the casetray (andthe end blocks). form a block,seeStep2.After the glue dries,
ENDBIrcKs.To makethe endblocks (A), cut this block to get two end blocks (A) 97+'l
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
sembly is complete pieceoff the panelthat's the length you just
you canbegin on the determined,seeFig. 8a.
lid panel (E). Start Next, placethe short pieceon the caseso
bygluing up enough the long beveledpoint is touching the arc.
stock to make a Now mark andtrim the end flush, seeFig. 9.
panel that's V+' uD sIDEs.To makethe lid sides (F), start
wider and |r longer by measuringthe thickness (height) of the
case.Then rip two piecesof Varrstockto that
than the trav. After it
dries,rip the panelTrorrwiderthan the tray.measurement(2rr)andcutthemto the same
ASSEMBLETIIE POCKET. NCXI, tO fOTM thc length asthe case,seeFig. 9.
pocket and lid top, cut the panel into two After the lid sides (F) are cut, fastenthem
parts,seeFig. 8.To determinethe length of to the tray with double-sidedcarpettape.
the pocket,measurefrom the endof the tray, HINGEScREwS.With the sides in place
to wherethe arc beginson the divider.Then you can drill the holesfor the hinge screws.
addVz"to allow for trimming. First, drill a 3/8r'counterbore,Vto|deep and
Vzttfromthe bottomend,seeFig. 10.Then.
drill a Tsrrpilot hole through the lid sides(F)
andinto the endblocks (A), seeFig. 10.Nou-
removethe carpettapeandenlargethe hole
in the lid sides(F) Lo7/3ztt.
Before screwing the lid sides (F) to the
casetray,placea Vazrr shimbehindeachlid
side (F). Now tightendowna No. 12round-
headscrewuntil the bottomofthe screwslot
is flushwith the lid sides(F), seeFig. 10a.
ASSEMBLE TIIE uD. Next, fit the remain-
ingpartoftheiidbetweenthesides,andtrim
the end flush with the top of the case,see
Fig. 9. Then glue the panel to the lid sides
(F) only.When the glue is dry, file the screw
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
sides (Varlround-over)and ends (Vz"round-
over),refertoFig. 12.Thenyoucanbegin on
the chisel rests (D) and tid stiffener (G).
RourINGrIrE nncn. Using the cut-offleft
over from making the end blocks (A) (refer
to Fig. 1),usea 3/8rr
round-overbit androut a
bullnoseon both ends,seeFig. 11a.
cuT To FIT. AJter the bullnoses are
complete,cut off two Vzrllongpieces, see
Fig. 11.Now, cut the chisel rests (D) to fit
betweenthe casedividers(B), andcutthe lid
stiffener (G) to fit betweenthe lid sides (F),
see Fig. 12. Finally, glue the pieces in as
shownin the CrossSectionon page9.
FINGERRECESS. The last step is to file a
3/4t'-widefinger recessin the bottom end to
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