DIY Network

Turtle Toy-Box: Sculpted Sides and Top From "Wood Works" episode WWK-702

	Dry-fitting the box pieces.
	Cutting the stock that will form the turtle's head.
	Sculpting the lid.

In this episode of DIY Wood Works, host David Marks creates a child's toy-box fashioned and carved to look like a turtle. In this second segment, the case is assembled and work gets underway on sculpting the sides and top.

Materials and tools used in this episode:

Alder stock
1/2" maple plywood
MDF for templates
Jointer
Table saw; cross-cut sled
Jig saw
14" band saw
Plunge router
Power grinder; arbor-tech blade
Disc sander
Random-orbital sander
Die grinder; ball-mill
Biscuit jointer; #20 biscuits
Sharp chisel
Small v-shaped gouge
Dead-blow hammer
Brad driver; brads
Wire cutters
Clamps
Yellow woodworker's glue
Glue roller
Slow-setting resin glue
Drawing paper
Carbon paper
Cheese cloth
Green stain
Non-toxic salad-bowl finish
Brass hinges
Safety lid-supports
Straight-edge
Carpenter's pencil
Felt-tipped marker
Safety glasses or goggles

Safety Alert: Always wear safety goggles or safety glasses, and follow proper safety precautions, when working with wood, power-tools, saws, drills, routers, etc.

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Figure A

Sculpted Sides and Top

• With the slots cut for the biscuit joinery, the shapes for the sides can be cut out using the band saw. Because of the thickness of the stock, David uses a 14-inch band saw to make the cuts (figure A).
  
  

  
  
  

• With the sides rough-cut out according the templates, a dry-fit of the side pieces can be done (figure B). With the pieces together, you can measure for the exact dimensions of the bottom panel.

• At the table saw, cut the bottom panel from 1/2" maple plywood. Our panel is 21-1/4" long by 15" wide.

• Test the fit of the panel with the box (figure C).

  Figure B

  Figure C

  
  

  
  

• Before glue-up of the box can be done, there are a couple of things still left to be done. One is to add more mass to the turtle's feet to allow additional stock for sculpting the outside. Using the side template once again, trace the profile of the feet onto a piece of alder stock that is 1-7/8" thick. Lay out four profiles, with the grain running in the same direction as the sides (figure D). Extend the lines using a straight-edge.

• Cut out the four shapes at the band saw (figure E). The additional pieces will be glued on later, during the overall glue-up.

  Figure D

  Figure E

  
  

  
  
  

• Another step before glue-up is the sculpting of the interior walls of the box. This will add dimension to the inside of the box, but it's easier to do this step now, before the box is assembled. To carve and shape, use a power grinder with arbor-tech blade installed. The three carbide teeth of this tool allows a smooth, sweeping action to remove wood quickly (figure F).

• Sculpt to about 1/2" from all three edges and from the dado.

• Use a long straight-edge and ruler to periodically check the depth of the cut (figure G) as you carve out the center.

  Figure F

  Figure G

  
  

  
  
  

• Grind the shape down to within about 1/4" of the target-depth of 1-1/4" deep in the center. Then switch to a disc-sander, with 24-grit paper, to smooth out the rough shape (figure H). Use a feathering motion, going from the edges toward the center, to avoid the risk of cutting outside the lines.

• Repeat the grinding process with all four sides of the box.

• Before glue-up, use a brad-driver to insert three small brads into each leg. Snip off the tops of the brads (figure I), leaving a tiny nub exposed. During the glue-up, the clipped brads will help prevent the additional leg-stock from slipping out of registration.

  Figure H

  Figure I

  
  

  
  
  

• For assembly and glue-up, use slow-setting plastic-resin glue to allow for plenty of assembly time. Apply glue to the slots and biscuits, then to the dado.

• Gradually assemble the pieces of the box, including the plywood bottom-panel (figures J and K). Use a dead-blow hammer to tap the pieces together.

  Figure J

  Figure K

  
  

  
  
  

• Trace on the shape of the additional leg-stock, and apply resin glue to both the box and leg.

• Position the leg-stock (figure L) and secure with small clamps. Repeat for all four legs.

• With all of the box pieces in position, pull the joints tight with clamps (figure M).

  Figure L

  Figure M

  
  

  
  
  

• While the glue cures on the box, you can return to working on the top. At the 14" band-saw, and using a 1/4" blade, trim off the excess stock around the head and tail (figure N).

• Next, transfer the lines from the template to delineate where the box meets the top (figure O). Using these lines, you can begin to sculpt out a concave shape, similar to the ones carved in the inside faces of the box.

  Figure N

  Figure O

  
  

  
  

• As before, use the power-grounder with arbor-tech blade installed to carve away the material from the bottom side of the lid (figure P).

• For accuracy, measure the depth as you carve. Once complete, the depth should be about 2-3/4" at the center (figure Q).

  Figure P

  Figure Q

  
  

  Figure R

  
  

• Finally, use the disc sander with 24-grit sandpaper to feather and smooth the surface (figure R). Continue smoothing until the surface matches the interior walls of the box.
  

  
  

  
  

  RESOURCES :
  

  The Small Wood Shop (The Best of Fine Woodworking)
  Author: Helen Albert (Editor)
  Publisher: Taunton Press
  ISBN: 1561580619
  

  
  Woodworking Techniques: Best Methods for Building Furniture from Fine Woodworking
  Author: Editors of Fine Woodworking magazine
  Publisher: Taunton Press
  ISBN: 1561583456
  

  David Marks Website
  David Marks, DIY's Wood Works host, is a master woodworker. For more information on cut sizes and project details, please contact him via his Website at www.djmarks.com
  

  
  Woodworker's Guide to Wood: Softwoods, Hardwoods, Plywoods, Composite, Veneers
  Model: 080836878
  Author: Rick Peters
  (2000)
  Sterling Publishing Co. Inc.
  Website: www.sterlingpub.com

  Fine Woodworking
  A magazine devoted to high-quality craftsmanship in woodworking.
  The Taunton Press Inc.
  Website: www.taunton.com

  ALSO IN THIS EPISODE:
  	Turtle Toy-Box: Stock and Joinery
  	Turtle Toy-Box: Sculpted Sides and Top
  	Turtle Toy-Box: Sculpted Shell, Head and Neck
  	Turtle Toy-Box: Finishing Touches