Part Two of my toy box build.

I'm going to spend a little more time on the toy box today. I need to get it completed as soon as possible. I have to deliver it next weekend.

This is the bottom of the box. It needs a round-over detail routed on the front and both sided.I am using my router table but a hand held router will do fine for this job.  

This picture shows a small round-over I routed on three sides. 

While I had the router table set up I worked on the lid also. I did the same three sides but on the lid I did the top and bottomto give it a bull nose effect.

I set the box on the bottom. Make sure it is lined up with equal space all around. 

Use a square in one corner to make sure the box is squared up. If you screw it down out of square the lid will bind. Start with one screw then make sure it's still square. As you install more screws keep checking it.   

Here is the box with the bottom installed . Notice the over lap of the bottom. Notice that the front paned is set back from the sides by 1/2". I'm going to install the child's name on the front using 1/2" thick MDF. The recessed front panel will Let the letters sit back a little. 

The next step is to plug the pocket holes. Kreg sells these plugs along with the screws. Put a little glue in the hole and install the plug. 

Install a plug in every hole. Let the glue dry for a while before you start sanding them flush. 

A sander and some elbow grease is needed to get the plugs flush. The better you get the sanding done here the better the paint job will look.  

I'm going to finish up this session by easing over all the sharp edges and do some prep sanding. MDF has very porous edges. If you don't prep it right you will have trouble getting paint to cover the edges. I'm going to sand the edges as silky smooth as possible going through the grits. I'll sand down to at least 220 grit. In the next session I'll make a solution to apply to the edges to seal them. This sealer will keep the paint from soaking in so bad. I'm going to take a break and do some more work tonight. 




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