DIY Network

Turtle Toy-Box: Stock and Joinery From "Wood Works" episode WWK-702

	This toy-box made to resemble a turtle is something that children will find both useful and fun.
	Carving the turtle's shell and head allows you the opportunity to test your wood-sculpting skills.
	The box's interior and exterior are sculpted using a power grinder. Brass hinges attach the lid, and safety lid-supports prevent the possibility of the lid closing on little fingers.

In this episode of DIY Wood Works, host David Marks creates a child's toy-box fashioned and carved to look like a turtle.

A totally whimsical project, this turtle toy-box is crafted from solid maple. Carved in a stylized design, it provides storage space that's ideal for toys, books or games, and is sturdy enough to provide a place for a child to sit to read a book or tie their shoes. Since it's designed for children, the top is attached with child safety hinges to prevent accidental closure, and the hinges close slowly to protect little ones' fingers. A highlight of this project is David Marks' demonstration of the process for dying the wood for lively "turtle-like" colors.

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

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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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Templates and Material

The turtle toy-box has two main parts:

• the shell top sculpted from several layers of alder glued together, and
  
• the box, made with biscuit joinery and sculpted both inside and out.
  
  

Figure A

Figure B

Using that information, he then created templates for the sides and back. Markings indicate the location of the biscuit joinery and the dado that will hold the bottom panel. The template cut-out also includes the shape for the turtle's legs (figure C).

For the stock, David selected alder, a relatively "soft" hardwood that's easy to shape and holds sharp details when carved. The 8/4-stock was milled into 9"-wide boards that are 1-7/8" thick. This thick stock provides extra material for shaping. The top is made by edge-gluing two 34" boards to a single 44" center-board (figure D). The ends of the longer board will later be carved to form the head and tail.

Figure C

Figure D

Stock and Joinery

• In addition to edge-gluing the top, edge-glued the sides of the box -- which will be made of two edge-glued boards 16" long for the front and back, and two edge-glued boards 27" long for the sides. Cauls and clamps are used to ensure that the boards are glued up flat (figure E).

• With the boards glued, the template can be laid out for the top. First, align the center-lines on the template and stock for the top, then trace on the shape for the shell (figure F).

  Figure E

  Figure F

  
  

  	Figure G
  	Figure H

  
  

• Cut out the pattern using a jig saw (figure G).

• Use a hand-scraper to smooth the glue lines.

• To achieve greater mass for sculpting the crest of the shell and the head, more alder stock needs to be added to the top. Mill another piece that's 10" W x 1-7/8" thick, and cut it to 43" long. Joint one face. You'll attach the jointed side, aligning the center lines.

• Using yellow glue and a glue-roller, spread the glue evenly down the center of both the top and the extra stock.

• Position the extra stock, aligning the center lines, and use clamps and cauls to hold the pieces secure, and under even pressure, as the glue hardens (figure H). The top will be trimmed to shape later.
  

  Figure I

  
  

• At the table saw, evenly trim the case-stock to proper dimension. Begin by ripping each piece to width.

• Then cut each piece to length using the table-saw and cross-cut sled (figure I).
  

  
  

• With the pieces cut, align the side-template for the box to the side stock, align the edges, and trace on the profile onto the side stock (figure J).

• Use the next template for the front and back of the box, and trace the shape onto the stock (figure K).

  Figure J

  Figure K

  
  

  
  

• While the case-stock is still square, lay out the dados for the bottom panel. The side stock should be cut with stop-dados (figure L).

• Through-dados should be cut in the front and back pieces (figure M).

• Using a plunge router, with the fence referenced against the base of the stock, cut the dados 1/2" wide and 3/8" deep.

  Figure L

  Figure M

  
  

  
  

• The case will be assembled using biscuit joinery. Mark for the biscuit slots on the side pieces, 5/16" from the marked line that represents the inside corners of the box (figure N).

• Use #20 wood biscuits, and space the biscuit slots so that they are 1/8" apart.

• Cut the matching slots on the ends of the front and back pieces so that they are also 5/16" from the inside edge. Use an MDF spacer to align the biscuit-slot cutter to the stock as you make the cuts. Use pencil-lines to define the layout of the slots. Note that the slots are offset off the inside edge to allow more room for sculpting (figure O).

  Figure N

  Figure O

  
  

  
  

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