Tools and Materials
Rather than simply list tools, I've attempted to categorize them according to function since the woodworking techniques used in box call making are relatively simple, and each procedure can be accomplished with several different tools. I'm not a master woodworker or carpenter myself, but did learn how to safely use most power tools while working as a display builder for a large department store chain, and (briefly) as a cabinet and casework installer. I also (much to my wife's dismay!) try and handle most of the repairs around the house--which means I've made a ton of mistakes. In short, I would strongly encourage anyone not familiar with power tools to learn how to store, maintain, and operate them safely.
- Resawing to proper thickness
- Table saw or band saw
- Ripping (cutting along the grain) to proper width
- Table saw; band saw w/fence
- Crosscutting to length (w/power tools)
- Table saw; band saw; "chop" (power miter) saw; radial arm saw
- Crosscutting (by hand)
- Miter box w/backsaw; hand saw with jig or straightedge
- Dadoes
- Router table; table saw; router (freehand w/guide fence)
- Shaping lid/handle
- Scroll saw;Jigsaw/sabre saw; coping saw
- Shaping lid radius
- Belt sander; power sanding station; random orbit sander; planes, rasps, files, and chisels
- Drilling
- Electric drill; cordless drill; brace (hand-powered drill)
- Finish sanding
- Detail sander; palm sander; sanding block and freehand sanding
- Other useful tools and supplies for call making
- Utility knife; cheap paintbrushes; bottle caps (for holding small amounts of glue);
Assembly:
- Clamps
- Most types of clamps work fine, and the cheapest c-clamps in various sizes will do nicely. For assembling calls I usually use the 3" c-clamp for the end blocks, and bar clamps for the sides.
- Glue
- There are a lot of good wood glues out there. I've been using plain Titebond II (indoor/outdoor) yellow wood glue successfully on mahogany, walnut, cherry, poplar, and cedar. More exotic oily or resinous wood may require a more "serious" glue.
- Screws
- Wood screws with a smooth shaft between the head and where the threads begin permit the lid to move freely while calling. I like slotted (as opposed to phillips) brass screws with a round (first choice) or flat head. For most of my calls I use a size 8, 1 1/2" screw, though I have used a size 6 with good results.
- Springs
- I typically use springs that are about 1/2" - 5/8" long and about 1/4" in diameter, with a moderate tension--not too flimsy, not too stiff. I have found them at home centers, hardware stores, and occasionally on broken toys and equipment around the house. Spring manufacturers are another possible source. When I find a bunch I can use, I snatch up as many as I can since I never know when I'll run out. Also, if I find longer springs that are of the right diameter and stiffness, I snip them to the right length with wire cutters.

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