A few weekends ago I was doing some final fitting for the lid of my tool chest, and I just wasn’t happy with it. No matter what I did to shape the tenon shoulders, I just couldn’t get a nice crisp joint. In retrospect, the tongue-and-groove joint between the frame and panel may have been too tight, causing binding that prevented the mortise pieces from being drawn all the way in. Taking a few shavings from the bottom of the panel probably would have made for a more slip fit and allowed the frame to come together more tightly.
The thing was, though, I wasn’t happy with the grain of the wood I chose for the frame, anyway. I really didn’t end up with great frame pieces, and I ended up with plain-sawn boards that weren’t telling a coherent story at all.
On top of that, this was the first project of any size I’d attempted from poplar, and I haven’t enjoyed it. If I had it to do again, I would make the extra effort to find some tight-grained eastern white pine, which I enjoy much more. The poplar seemed very stringy, bending and crushing instead of slicing or chopping under the chisel. With more experience, I’m sure I’d learn some tricks for overcoming that tendency, but the project was dragging on and I was ready to move on.
It was time to start over on the frame, so I followed my instincts and reached in to my stash for some walnut.
I stewed about it that Sunday evening and Monday morning, thinking about how to move forward. After some encouragement from my family (they’re handy that way), I pulled out some of my remaining walnut stock on Monday evening. It was all rough-sawn, so I planed a small area with my block plane to get a sense of the grain.
I found some pieces with strong linear grain that looked promising. There were some knots to work around, but as I measured, I found that the knots fell nicely between sections of arcing riftsawn grain in a way that offered good lengths for each piece of the frame.
The next weekend I got enough time in the workshop to fit the tenons for the new frame. I made sure to adjust the thickness of the panel for a slip fit in the frame, which came together sweetly. I glued up the lid early Sunday evening and celebrated with a beer.
There are differing opinions on whether to keep lumber on hand or to buy it per project. As small as my shop is, there’s a certain logic to taking a just-in-time approach, having only the material on-hand that you’ll use for your current project. The thing is, though, the just-in-time approach doesn’t give me the freedom to explore and compose the way I can with a generous stash of wood. I find myself making compromises, settling for what the lumber retailer has on hand. (The one exception I find to this is sheet goods. I hate having a bunch of plywood hanging around.)
Having the lid glued together has accelerated this project, which is good because it’s time for this chest to start paying some rent. I took the time to shim up the left rear wheel so that the chest sits level, and then I moved on to making the wall for the wooden planes at the back of the chest. For the wall, I planed a thin piece of Douglas fir, ripped it to four inches wide, and made cleats from the offcut. The Douglas fir was reclaimed from a workbench a friend of mine gave me that had been his grandfather’s. It was a rough piece made from dimensional lumber, so this has been an exercise in “upcycling.”
The saw till is more reclaimed lumber from that workbench, including a piece of eastern white pine for the wall, which planed very sweetly.
Tomorrow, I plan to move on to the dovetails for the large sliding till.