Sine Wave Box

Sine Wave Box

If you have a new idea or just want to test out something build a box.  I came up with this design for a sine wave pattern. The challenge was to create the sine wave cut with out a CNC machine. Box building is perfect for new ideas and your “I never done this before” test. Material for a box build is minimal and not that expensive.  Plus you get a great looking box, if things work to your favor. 
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Because this will be going into a frame to create a box it’s going to need some rabbits. I cut 1/4″ X 1/4″ Rabbit along each side of long grain.
The jig used worked fine. After doing the project wish I had made a different one. The main board should have been longer to make the cut easier. The board on the bottom should have been longer as well to clamp down independent of the main top board. All said and done two board to make a quick jig. It has 1/4″ slots for bolts and t-nuts.
Square the front of the jig with the miter slot. The make mark where the blade is. Note: if you move the jig you have to make new marks.
have a second pair of pants ready, the pucker factor is high on this one. All kidding aside, this is dangerous. Its still pretty easy it’s just working your nerves a bit. With your lay out lines set you can use the marks from the blade that you made and this let you know where to slowly drop the work piece on the blade.
I used a blade height 3/8″ this gave me a radius that required to move the work piece closer by 1 3/4″ for each phase. Each row was 1″ wide. The video does the EXPLANATION more justice.

If you complete each phase you should end up with something like this. Don’t for get to do the rabbits on each end before going on to sanding.
Sanding was not very fun on this project. I spent 3 nights sanding just the lid piece. Use what ever you can to make it easier and faster for you. Tip: use a flash light to see any deep scratches. 

Pre-finish the lid and the bottom of the box. let that dry while building the rest of the box.
The rest of the box is standard construction. 45° miters on the corners. Walnut splines and brass hinges.