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On episode 202 Bob and Rick Rosendahl explain how we can make a tissue box cover. Apart from that we will also be looking at how to splice joints using dovetails, how to make the perfect box joints, how to use a non-plunge router for internal cuts and the best way to trim a lid. Now let's watch Bob closely in the workshop to see how these things can be carried out without any difficulty. In the first place make sure you have removed your watch and any jewelery that you are wearing and roll up your sleeves to keep them out of the way of the router.

Today Bob is going to start with a dovetail bit. This is a regular dovetail bit that Bob is using and this needs to be fitted into the router. Bob is also fitting an insert on the top of the router and tightening it up from the backside. The plunge router is then fitted back into the table mount from where we can carry out today's task of making a tissue box cover.

Bob has a neat little fixture which he uses when doing any dovetail work or any fixed joint, which is known as a spacer fence with a 3/8 bar as far as can be seen. This fence also has screws on the sides which help in holding it down on the table mount. The height of the bit will have to be adjusted and left at 5/16 of an inch. You can also start off with a couple of test pieces, which will help you understand whether the height of the router has been set to the desired levels. Clamp the two test pieces together and make sure they are flush in line with the spacer fence. You could use a hammer to tap them a little to make sure that they are exactly as you want them to be. You would also want to know that you are whether you are square with the fence or not. To get this in order you could use to have a little push block behind the test pieces, and you would be well on your way to cutting the dovetails out.

Cut out the first dovetail which will be the hole that fits over the fence. Make sure that the hole is of the right size, and then you can go ahead and cut the other dovetails that you need. The only thing you need to do after this is to make sure that the two pieces fit together without anything holding them apart. Right now we seem to have a perfect fit. Now that we have the test pieces fitting together let us start the tissue box.

For this task, Bob is using a piece of white wood and walnut which he has clamped together and ensured that they are flush in line with the fence. Having done that Bob is ready to start cutting the dovetails. This particular piece after being cut has an offset which has to be rectified. Therefore, Bob corrects the offset and cuts the dovetails on the other side of the wood all over again to ensure that he has a perfect fit. True to Bob's estimate the second attempt turns out into a perfect fit which completes part one of the tissue boxes.

Next Bob is going to show us how we can put two pieces of Mitre together. In this case, Bob has made sure that he has clamped a number of pieces together to ensure that the wood does not chip from either side, and the dovetails are cut uniformly. Clamping the pieces together looks like a big task but is rather easy once you take a look at how Bob manages the entire matter. The whole idea is to get the pieces in the right way and flush in the cutting area of the router. Once he is through with the cutting you can see that the pieces are perfectly matched and fit together as they were required to be.

Now it is time to cut some box joints with a 3/8 Cutter, which is a spiral bit and fit it into the router. The height of the bit should always be the thickness of the material you will be using. As we are now cutting the sides of the box it is also necessary that we mark the pieces. You also have to take care about an offset that will be required. You can start with a pair, but you will have to clamp the pieces together before you begin. The procedure is the same as what we have explained earlier with the sole exception of the router bit being changed. We are now cutting box joints and not dovetail, which is the only difference that will be noticeable. Let us go ahead the cutting, and you will notice that we have a perfect fit out here again. Now you will have to carry out the same task for the other side of the box. Once we are through the other side, we only have to glue them together and start working on the top of the box.

Rick is going to explain about how the top can be done by using a non-plunge router. One of the first things that Rick explains is the difference between working on a plunge and a non-plunge router. Unlike a plunge router where you have full control over the movements a non-plunge router will not give you a similar freedom. You will have to ensure that you have a pre-cut hole which will help you preset depth of your tool. Rick has cut a hole in the blank to enable the router to work freely and cut the shape that is required. The whole idea when using a non-plunge router is to move the router in a clockwise direction rather than an anticlockwise direction. It is also important for you to cut into the precut hole until you reach the edges of the design you want on the top of the box. You will also have to ensure that you go to a little slower on the sides as the debris is likely to accumulate in the corners and not allow you to have a proper cut.

Rick first starts at the center and moves around in a clockwise direction until he has a better part of the wood cut. However, there is some sawdust accumulated at the sides which has to be cleaned and the entire procedure repeated to ensure that we have a clean cut without any debris lying around. Once the procedure is repeated Rick has a perfect piece which is ready to be used as the top of the tissue box. The only thing that needs to be done is for the top to be glued onto the box using four small Finnish nails that are cut according to the requirements.

Finally, it's time to use the round over bit. Rick is using a half inch round over bit with a flush top on it. This is going to run flush to the edge of the piece and round of the edges of the tissue box. This seems to be the easiest part of the entire project and Rick finishes this within no time.

As far as I as a learner am concerned I am happy to have learned what was imparted by Bob and Rick Rosendahl and hope that I have been able to explain this project to the best of my ability. I hope that you too will enjoy looking at the series of videos, which are available at. I will see you again within a short time a new episode and hope that we can all learn something new again.

Hi folks,

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Harish is viewing all the Router Workshop videos, and then writing about the information he has picked up from a selected video. Looking at the way this man has been going ahead with his job, I feel that his articles can be of interest to those who want to follow his example. Join this special video series by clicking the link below and you can get all information you need about the right usage of a router and the many ways you can use it to generate income for yourselves. Don't miss out on the benefits but start learning today and avail the benefits as many beginners are doing.

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