- Wood for end blocks
- I usually use a 1 or 1.5 x 2 in a variety that contrasts with the rest of the box. It's not necessary, but it's my one attempt at being decorative. If the box is mahogany, I generally use walnut for the blocks, and if it's poplar, I use cherry. I try to make the base and sides out of the same material, and the lid and end blocks out of the same material. Whatever the wood, it should be free of splits (even small ones), checks and knots since wood with those kinds of defects will most likely split along the grain when drilling the hole for the hinge screw.
- Cutting end blocks
- The only considerations here are to be sure they fit precisely between the dadoes. If they're too wide or narrow, they won't seat flush in the dadoes or against the sides and the box won't be tight or sturdy and probably won't work very well. I cut mine tapered, around an 1" at the bottom and no more than 1 1/4" at the top. The blocks should be cut so that the grain is vertical (perpendicular to the base when assembled). Cutting a few endblocks by hand is easiest with a backsaw, and the wood clamped in a miter box. Again, I have another little jig for cutting most of my end blocks, and I'll post a picture or plans for it as soon as possible. However it's done, the plane of the cut must remain perpindicular, so the saw must be kept perfectly straight. . .Even if tapered, the sides should still be cut so that the bottom and top of the end blocks are square. If not, when assembled the sides won't fit flush against the sides of the end blocks. In this case, a picture is worth a thousand words, and I'll post one as soon as possible.
- Another method for cutting many blocks at one time can be accomplished on a table saw by tilting the saw blade a few degrees and ripping a piece of narrow stock with the grain parallel to the face of the end block and the bottom is sized to fit between the dadoes in the base. This will produce a long trapezoid or dovetail-shaped piece which can then be crosscut by hand or on the table saw to produce any number of end blocks at once (sort of like slicing off a roll of store-bought cookie dough). This method takes some set up time but it's worth it.