Maxy's Hideout

A. Materials List: QUANTITY LETTER NAME SIZE MATERIAL 1 A Top 3/4" x 6" x 18 1/4" Oak 1 B Top/Face 3/4" x 1 7/16" x 15" Oak 1 C Lid 3/4" x 8" x 14 15/16" Oak 1 D Bottom/Face 3/4" x 2 3/8" x 15" Oak 1 E Bottom ¾” x 11” x 18 ¼” Oak 2 F Sides ¾” x 10 ¼” x 10 ½” Oak 1 G Back ¼” x 15 ¾” x 11 ¼” Oak 2 H Back Nailers ¾” x ¾” x 15” Oak 1 I Front/Face Nailer ¾” x 1” x 15” Oak 1 J Letters 1/8" x 2 3/8" Oak 1 K Knob Brass B. Bread Box Cutting Procedures: Select an oak board 1" x 11 1/2" x 76". All pieces can be cut from this size board. Use a jointer to joint one edge of the board. Use a planer to plane board to 3/4" thick. Use a radial arm saw to cut pieces to appropriate length. Use a table saw to rip pieces to appropriate widths. Use a jointer to joint the other edge of each piece. Use a band saw to cut the angle for each side (F). Use a belt sander or a disk sander to smooth out the angled edge of each side (F). To make the dado joints for the back (G), set the table saw blade to cut 3/8" deep. Next set the fence next to the saw blade to cut the inside/back edge of each side (F). Move the fence 1/8" away from the saw blade and repeat the cuts to the sides. This should allow the thickness of the back (G) to fit flush. Use a portable hand router and a 1/2" Roman -Ogee Bit to route the outer edges of the top (A) and bottom (E). Use a portable hand router and a 3/4" straight bit to route a 1//8" deep recessed area inside the design of the lid (C) to provide for the lettering. Place a 2 1/2"" wide board on top of another slightly larger board and plane the top board to 1/8: thick. Chose a desirable block lettering 2 3/8" high and trace the letters (J) "BREAD" onto the thin board just planed. Use a scroll saw to cut out the letters. Adjust the table saw blade to 30 degrees and rip the top and bottom edges of the top/face (B) and the lid (C). Also rip one edge of the front/face nailer (I). Cut the back (G) to fit properly after the assembly is completed. Also drill six 1/4" equally spaced holes in the back for ventilation. C. Wooden Bread Box Sanding Procedures: Rough sand all parts with an orbital sander and 80 grit sandpaper. Intermediate sand all parts with an orbital sander and 120 grit sandpaper. Rough and intermediate, sanding should be completed before assembly procedure. Finish sand all parts with an orbital sander and 220 grit sandpaper after the assembly procedure. Hand sand the lettering with 220 grit sandpaper prior to gluing them on the lid. Hand sand all edges, details, with 220 grit sandpaper just prior to the finish procedure.  D. Bread Box Assembly Procedures: Place glue on the ends of the back nailers (H), and position them flush with the dado joints and top and bottom edges of each side (F) and nail them into position Nail through the sides using a nail gun and 1 1/2" nails. Place glue on the beveled edge of the front face nailer (I), and nail it to the top inside portion of the top face (B). Place glue on the ends of the front/face-front/face nailer assembly. Position the assembly flush with top and front edges of the sides (F) and nail them together. Place glue on the ends of the bottom face (D) and nail it into position. Turn the top (A) upside down. Place glue on the top edges of the sides (F) and the nailers. Place into position on the top and secure by nailing through the nailers. Place glue on the bottom edges of the sides (F), bottom face (D), and the nailer (H). Place the assembly in proper position on the bottom (E) and nail through the under side of the bottom to secure it into position. Sand the recessed area of the lid (C) until smooth. Place glue on one side of the letters (J) and place them into position in the recessed area of the lid (C). Use a nail gun and 3/8" brads to secure the letters. Place the lid (C) into position and use a nail gun and 1 1/2" nails to place one nail into each side (F). These nails should be positioned 3/8" in from the slanted edge of the sides and 2 1/4" from the under side of the top (A). These two nails serve as the hinges for the lid. Place the back (G) into position in the dado joints of the sides (F) and nail securely with 1/2" nails. NOTE: The back should be attached after the finish procedure is completed. Drill hole in lid (C), insert machine screw and attach knob (K). NOTE: This should be done after the finish procedure is completed. E. Bread Box Finish Procedures: Use plastic wood dough to fill all holes, cracks and imperfections. Hand sand all edges with 220 grit sandpaper. If stain is desired, apply with a brush and allow to dry penetrate for 5-10 minutes, then remove with a clean rag. Allow stain to dry 6 hours and then repeat with a second coat. Apply a clear finish coat such as Varathane, Polyurethane, etc. using a pure-bristle brush. Allow to dry 12 hours. Lightly hand sand finish with 220 grit sandpaper. Apply second coat of clear finish. If additional coats are desired, be sure to allow the finish to dry properly, then lightly hand sand with 220 grit sandpaper between coats. Allow final coat to dry 24 hours before using your wood bread box. If stain is not desired, continue with steps #5-9 after step #2. Congratulations, your wooden bread box is finished and ready to use!