“SHUT THE BOX” GAME

GET FROM ROCKLER

Stock # Item59032 Rockler Router Table

Box Joint Jig38238 3/8" Spiral Up-Cut

Router Bit (1/2" sh.)11040 Solid Brass Side Rail

Hinges (1 pk.)46818 Decorative Swing

Latch - Brass31022 1/2" x 5" x 48"

Walnut Lumber (1)33815 1/2" x 5" x 24"

Walnut Lumber (1)65100 1/4" x 3" x 24"

Walnut Lumber (1)35553 1/2" x 5" x 24"

Curly Maple (1)21014 1/2" dia. x 36"

Walnut Dowel Rod20735 5/16" dia. x 36"

Birch Dowel Rod49897 1/4" x 24" x 48"

Walnut Plywood51706 Titebond II Dark

Wood Glue

www.rockler.com800-279-4441

OTHER MATERIALS

• Adhesive backed numbers• Your choice of finish

Printed in the USA 56099 Rev. 7/18 © 2018 Rockler Companies Inc.

1. CUT THESE PIECES

“SHUT THE BOX” GAME2

1/2" THICK WALNUT

1/4" THICK WALNUT VENEER PLYWOOD

5/16" DIAMETER BIRCH DOWEL

1/2" THICK MAPLE1/2" DIAMETER WALNUT DOWEL

1/4" THICK WALNUT

14"

1 1⁄8"

1 1⁄8"

9/16"

1 1⁄8"

3 3⁄8"

3 3⁄8"

1 3⁄4"

2 1⁄4"

2 1⁄4"

10 1⁄2"

13"

2 1⁄2"

1"

1/2"

9/32"5/16" hole

13"

13"

13 3⁄8"

9 1⁄2"

9 7⁄8"

x10

x2

x2

x2

x2

x2

x2

x2

x2

x1

x1Drill 5/16" through hole centered 3/8" from bottom.

Chamfer corners.

x9

x1

A

D

E

F

H

G I

J

J

B

Router table jig makes cutting box joints easy

Use the Rockler Router Table Box Joint JIg (59032) and a 3/8" Spiral Upcut Router Bit (38238) to cut 3/8" box joints in the pieces as shown at left.

Be sure to follow the instructions included with the jig and orient your pieces properly when routing to ensure symmetrical joints.

C

L M

11⁄4"

3/4"Drill 5/16" through hole in both pieces.

Cut slightly long and miter to exact length on assembly. Ease top edges by routing 1/4" round-over.

See Appendix on Page 5 for tips on making these.

56099 Rev. 7/18 © 2018 Rockler Companies Inc.

“SHUT THE BOX” GAME

2. BUILD THE BOX

B

B

A

A

C

ED

D

C

E

Stopped groovespreserve fingersThe grooves in Parts A and E must stop 1/4" short of both ends so that they won’t be visible when you glue up the box.

Special glue tools and clamping caulsdeliver better, easier box-joint glue-ups

Rockler’s 3-piece set of Glue Paddles (48844), Box Joint Cauls (32993) and 1" x 15' Band Clamp (58432)are designed to make glue-ups simpler and more precise.

The hinges require 5/16" wide x 1 5⁄16" long mortises centered on the rear-facing top edges of Parts B and the rear-facing bottom edges

of Parts E. Rockler’s JIG IT Hinge Mortising System (58822, sold separately) and dedicated template (56612, sold separately) make accuracy easier to achieve.

Rout mortises for side rail hinges

Rout a 1/4" wide x 1/4" deep groove 7/16" up from the bottom in Parts A and B.

Note: The groove must stop 1/4" from the ends of both Parts B so as not to ruin the fi nger joint.

Rout a 1/4" wide x 1/4" deep groove 1/16" down from the top in Parts D and E.

Note: The groove must stop 1/4" from the ends of both Parts E so as not to ruin the fi nger joint.

A

E

B

Apply wood glue to the joint fi ngers but not in the grooves. Clamp the assemblies, checking to make sure they’re square.

356099 Rev. 7/18 © 2018 Rockler Companies Inc.

“SHUT THE BOX” GAME

3. ASSEMBLE GAME SECTION

5. ADD LID SUPPORTS

4. APPLY FELT TO BOTTOM

6. INSTALL THE HARDWARE

G

IJ

K F

H

L

L

M

M

G

Apply wood glue to the joint fi ngers and clamp the assembly. Do not glue the dowel assembly.

Paint the numbers on the fl ip blocks (Part J) or apply adhesive-backed numbers available at a craft store.

Pressure Sensitive Felt - Black22822

Note: Miter corners of all pieces

Attach pieces with wood glue.

Install this piece fi rst, resting it on game assembly to set height.

Decorative Swing Latch46818

Solid Brass Side Rail Hinges (1 pr.)11040

Apply your choice of fi nish.

456099 Rev. 7/18 © 2018 Rockler Companies Inc.

“SHUT THE BOX” GAME5

APPENDIX: MAKING DOWEL SPACERS

Cut the 1/2" walnut dowel into 6" lengths. At a drill press, drill a 1/2" hole in a 3/4" thick piece of scrap wood that’s large enough to be clamped to the drill press table. You will insert the dowel pieces into the hole to hold them perfectly vertical for drilling.

With a zero-clearance fence on your miter saw, make a mark 9/32" from the blade on the off cut side. This reference will help you cut uniform pieces without measuring each time.

Use a center fi nder or other method to mark the center on one end of each dowel piece. Install a 5/16" brad-point drill bit in the drill press. Insert a dowel piece in the scrap block, center the dowel under the bit and clamp the block to the table.

Line up the end of the dowel piece with the mark and use a small piece of painter’s tape on the off cut side to capture the cut piece. Hold or clamp the dowel against the fence and cut the piece.

Holding the base of the dowel with a clamp or pliers, slowly drill into the end of the dowel, backing the bit out frequently to clear chips. Stop when you’ve gone as far as you can or when you notice the bit wandering off -center. Repeat for other dowel pieces.

Repeat the process until you see that the holes in the off cut pieces aren’t centered. Cut the other dowel pieces until you have 10 spacers with centered holes.

56099 Rev. 7/18 © 2018 Rockler Companies Inc.