v   Bethany asked whether readers are getting sick of Incra Jig projects. I don't  know, but I hope not. The Business Card Case will be the last one that we do from the project book—as least the last one we will photograph and cover here.    But we both agree that having done the jewelry box and the wood hinges, any project in the book is easy to do. When we approached the Business Card Case, we found that there are quite a few precise and difficult steps, but they very similar to projects/tasks that we had done earlier.    The inset picture is from the Project Book—you will have to wait a bit before you can see ours.     We searched through the woods that we had and found several species that we thought would make attractive cases—figured maple, walnut, cherry and black limba.    Bethany decided to use a piece of figured maple to start. Here, Bethany lays out the area of the board that she will use to make the first case.   The first step is to run the stock through the thickness planer. The instructions call for 3/8" thick stock, so Bethany runs each of the boards through the planer.    We learned in the making of the wood hinges, that getting the thickness exactly to 3/8" is extremely important. The inset shows Bethany using a thickness gauge which she did after every pass...and at different locations.    We have both found on earlier projects that the exact thickness is important. Taking off about 1/32" per pass works well particularly with the figured stock and exotics. Bethany uses a thickness gauge at several points after each pass.   Bethany edges one side of each board.    At the table saw, she cuts the stock to the exact dimensions called for in the Project Book. Using the Incra Miter Gauge with Incra Stop (inset) makes for very accurate duplication of cuts.    The instructions call for making some push blocks that are used to handle the small components.    At the router, Bethany installs the 3/8" full radius bull nose bit and sets the router height so that the radius of the bit is centered on the 3/8" stock.   She adjusts the auxiliary fence so that the bit is just slightly behind the fence. If you recall the making of the hinge, this is exactly the same cut. The inset diagram is from the Incra Project Book—with a drawing like this, it is hard to make mistakes. It is important to have that flat left on the stock so that the piece contacts the outfeed side of the fence. The minor flat will be sanded smooth in the final step.    She now makes the cut on edge of the blank using the push block and cutting with the grain. She adjusts the fence to 5" and rips the bull nose strip off the blank.    Now Bethany cuts the bull nose strip into two 2-7/8" widths. These two pieces will be attached to the finished case at the end and will serve of the rounded ends of the case. Main Menu -- and now available in  PDF File Next Page Go to Mfr.'s Site