A New Project - "The Ultimate Blanket Chest"

      It is time to glue the walnut corner posts to the longer boards — the ones that did not get rabbets.

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      Just as I did on the earlier joints, I brushed the glue carefully on every surface.

   A few wiggles back and forth and the dovetail cornerpost section slides into place.

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       It's a new day and I am back to sanding the cornerposts that I left to cure last night.
  

   Here is one end. The wood at the left is a scrap piece that I put in place to keep me from sanding over the crisp edges of the walnut.

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         After I have sanded the corners flush with the sides, I pass all the pieces through the thickness sander one more time.
   {Note: the fuzzy picture is result of dust in the air. I wear a mask, but no such luck for the camera. I use a can of air to keep the dust on the lens in check, usually.]

      To this point, all the router cuts have been made with one side against the fence. If you recall at the very beginning, I marked the sides so that all the cuts could be the same.
   The next cut will be from alternating sides. In order to make them accurately, I am planing the corners to be in line with the sides.

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   I am back at the Incra Jig. To make the final "C" cuts, I mount the Incra Stop on the fence. Per the instructions, I slide it towards the dovetail bit until the stop is as close as I can get it. This will be the starting point for the test cut.

   I make a test cut on one end. There are two cuts for every socket so I have to make 8 cuts.
  

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   The test piece is good, but the end panel (left) is a little proud. It measures about 1/16", so I will make that adjustment at the router table. It is just a matter of moving the Incra Stop back by that amount.

   No Sal today, so I place the vacuum hose as close as I can to the cutter. A lot of sawdust still gets by.

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   Totally impartial, my dear Samantha, fresh from the groomer, decides to plop halfway between the walnut and maple piles of dust.

   I couldn't wait to dry fit a few sections together. The dovetails, I just cut, fit perfectly. Here are two 6" sections dry fit together. It will give you an idea of how the final chest will go together.

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   Well, this is the challenge ahead of me — I have to close this gap. If you recall at the very beginning, I cut the boards about 3/16" wider than I needed. That extra was so that I could trim the finished corner exactly at this point.  I will make a jig so that I can register on the center dovetail of each board. If I trim based on the exact center point, I should have perfect corners.
   That is where we will pick up on this project next week. So far, I think it is looking good — I do love the precision that the Incra Jig gives me.

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