Ordinary Box

**Fencepost2** · 26th February 2010, 11:00 PM

Thanks everyone for the suggestions about the router speed. The straight cutter for the pins is only about 12mm outside diameter, though I did have it close to the top speed of the big Triton router which is about 24,000 rev and I would normally think that was okay. The really puzzling thing for me is that those pins that had some tearout had the tearout on the opposite side of the slot to what I would have expected. In other words, given the direction of rotation of the cutter it was on the opposite side to the one where the cutter would be pushing against the supporting board at the back. I think next time I am going to plunge even more gently than I did. Thanks again for the suggestions.

**Peter36** · 28th February 2010, 08:55 PM

Nice looking box and the splintering on the pins must have been patched well cos I could not see it. IMHO you do not need to glue the lid panel .
Cheers Peter

**driftit** · 10th March 2010, 02:43 PM

ive got an idea... Cut the DT's by hand hahaha

**ciscokid** · 12th March 2010, 06:32 AM

Very nice, solid looking box.

Router speed has already been mentioned a couple of times, but I would like to add sharpening the carbide router bit. I keep a couple of small diamond sharpening stones handy and touch up my bits as they get dull. You will get less splintering with a clean cut.

**rightendup** · 14th March 2010, 01:37 PM

Fencepost2,
So cool you are using the Golden Ratio in your box making (1.618).
You are on to something here.
Even the the pins could be in ratio of the Golden Mean.

**pjt** · 14th March 2010, 11:48 PM

For my money.... faster router speed is better than slow as u will be cutting smaller chips of wood, given the same rate of travel, the same effect is acheived when we slow the feed rate (whatever the operation (sawing drilling)) we take smaller chips and thus less likely to suffer chip out/tear out.

Burning can be from a blunt cutter or slow travel or dwell time at the end of a stopped groove,rebate or all of these things together.

Chipout normally occours as the cutter exits the wood, this happens on both sides of the board, one side of the slot (entry) and one side of the slot (exit) side of the wood (diagonally opposite) so as u have done backup the wood with sacrificial wood for one side but u might need to look at backing up the other side as well.

If I read ur post right u got chipout even tho u backed up on this side of the board, might there have been a gap or not clamped tight enuff or the grain direction, may have been very short grain right there at the exit point, can get chipout even if u have done everything right

have a close look at where u did get chip out and where u didn't and maybe something will show up

Just a few of my thoughts
Pete

**Fencepost2** · 15th March 2010, 10:08 PM

Thanks again for suggestions about tear out. I just made another box with the same materials and set up, but this time took about twice as much time and it seemed to do the trick - no tear out worth mentioning.

About the golden ration, 1.618. I learned something new today. If one dimension is 1.00 units and the other dimension is .618 units, 1.00/.618 gives you the ratio 1.618. But, in addition the difference between 1.00 and .618, which is .382, is in the same ratio to .618. That is, .618/.382 = 1.618. This means that a box in the proportions 5 deep, 8 wide, and 13 long satisfies the golden ration in a double sense.

**watson** · 15th March 2010, 10:11 PM

I'll bet your head hurts now

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