Pull Out Box Making

Here is the detailed process of making an only one pull out box with finger joints. The housing is merely a four-part element, the top and two sides and a back with stuck rabbets.

Overview


After calibrating the board I cut out the front, back and two sides but also the bottom that equalled a side height.

Milling Boards


I piled a stack of grooving cutters then adjusted height and depth cut. the same thing could have been made with a single saw blade.

Tooling


The black spindle ring against the fence plate purposed the same depth to be cut for all the sides clamped on the sacrificed block, along the mitre gauge. I machined the half of the side height then turned them upside down and went a second time through the cutter head.

Finger Joints


I made the bottom groove with the help of the continuity plate and the wheel module pressure. As the groove matched a finger height and I didn't want to go for a dropping-on operation I made the decision of cutting the front and back sides enabling for the little hole not to be seen from the front box.

Groove


It was time to machine the bottom with a rabbet due to the wood slightly thicker than the groove. The workpiece was guided along the spacer that I also held on the table with tape.

Bottom


Here is the stuck and trimmed box.

Assembly


Lastly I machined the recess on the table saw after adjusting the blade height with the help of rings and shims of the spindle moulder shaft, as I usually do.

Notch