Project: "Making Small Boxes"

	With the boards resawn and sanded to 1/2", it is time to start making the boxes. We will start by making a jewelry box for Beth.    Since we purposely resawed the butternut to give us pieces in order, we will make her box with mitered corners — and orient the pieces so that it appears to have continuous grain.    The first thing we need to do is to alter the Incra 5000 Miter Sled so that we can tilt the blade to 45o.
As you saw in the earlier pages, the beauty of the Incra 5000 Miter Sled is that you customize the installation by sawing the sleds to fit a particular blade — at a specific angle.    For that reason, we will make a right hand sled replacement that we will cut with the blade set at 45o.    Beth has removed the right hand sled and has laid it out, including the strip we cut away, and is measuring it.
	Beth cuts a piece of 1/2" Finnform to the size she needs. Finnform is not used in the Incra 5000 but should work for this custom right sled.    [I got the Finnform from Woodpeckers. — http://www.woodpeck.com  It is great for permanent jigs.]    By the way, Incra does offer a replacement right side sled ($25) which I would have used if I had thought ahead. I now have one on order, but hopefully, this one will work for the 45o blade angle.
Beth has installed the stacked dado set and the sacrificial fence for cutting a rabbet on the narrow piece. She uses the original (arrow) to set the width and depth.
	To help her copy the original, she tapes the original pieces onto the new panel. She has found the Forstner bit (left arrow) to equal the larger holes and the drill bit (right arrow) to match the screw holes.    The ease of assembly in the original was in part due to precisely drilled holes. Beth wants to do the same.
The drilling took very little time. She did not need to drill all three rows — just the ones that were used in the installation here.
	Her drilling was right on. All the holes match the tapped holes of the original.
Beth checks and double checks that she has set the blade tilt to 45o.
	Now she makes the cut with the blade set at 45o.
She attaches the cutoff to the aluminum miter bar. Again, all the holes match up.
	With the aluminum miter bar in the miter track, Beth makes the 45o cut on the new right side base.    She now has a new right side base for use when she wants to cut 45o miters.    Next week, we can cut the miters on Beth's jewelry chest. There is a lot to do but the project is coming nicely.