Author Topic: Ammo box (Read 4709 times)

Zulu · « **on:** April 01, 2010, 02:29:13 PM »

Here are a couple of pics of the ammo boxes I have started. They just show the dovetails. I'll post more as I progress.
Zulu

I'm building two chest. one pic shows ready for glue and one pic shows clamping.

Bucker · « **Reply #1 on:** April 02, 2010, 03:30:12 AM »

that is serious dovetailing? I don't know what those are called but it looks as though they will be strong. I do not have anywhere near that ability or tools.

Zulu · « **Reply #2 on:** April 02, 2010, 05:04:56 AM »

Bucker,
I have to admit that it takes no great skill level to make the dovetails you see in these pictures. All you need is one of these dovetail jigs.
There are craftsmen who cut dovetails by hand. Those are the guys with the talent.
Once I was set up, it took about 15 minutes to do one box.
Zulu

Zulu · « **Reply #3 on:** April 02, 2010, 10:37:53 AM »

Ammo boxes are finished. Now for the metalwork, handles, hinges, corner braces, etc.
Note the bottom of the box is held in with walnut pegs and sides are dovetailed. No nails or screws anywhere.
Zulu

Drilling Man · « **Reply #4 on:** April 02, 2010, 12:02:51 PM »

Pretty nice picts. Zulu... Over the years i've made quite a few oak tool boxes using half blind D. tails on the corners. It makes for a strong box, i also have the 24" Leigh jig for both half blind and through D. tails... It's much more complicated to set up and use, but it does turn out some excelent joints. For just a few though, i just cut them by hand as it's faster...

Good job on the boxes...

DM

Zulu · « **Reply #5 on:** April 02, 2010, 02:43:35 PM »

Drilling Man,
I can't even imagine how you cut them by hand. How do you get a tight fit? Are there gaps?
Zulu

Drilling Man · « **Reply #6 on:** April 03, 2010, 04:46:09 AM »

I only cut through D. tails by hand, it's really not that difficult... I cut the pins first by drawing them on the wood and cutting on the line removing the waste, usally with a bandsaw. Then i put the pins on the piece i'm joining to, and scribe around the pin, then removing the wood within the lines, and make it fit... lol

Just have good light and use something sharp to make your lines, so you get an accurate fit, it just take time and a little practise.

DM

Zulu · « **Reply #7 on:** April 03, 2010, 01:10:08 PM »

Started on the metal work for one of the chests today. The first two pictures are a chest I sold. This is the one I am trying to replicate with the metal work I did today.

First I take 1 1/2" X 1/8" flatbar and grind the design into it with a 4 1/2" side grinder. It took hours for what you see here and that's not all of it. After grinding, I heat it red hot in my propane forge and hammer it about a thousand times with a ballpein hammer to give it that beaten look. The long pieces will be the hinges and the small pieces will be folded 90 degrees and go on the corners of the chest. I still have to make a lock hasp and handles but I ran out of material. Have to get some more.
The anvil you see is 313 lbs.
Zulu

hillbill · « **Reply #8 on:** April 03, 2010, 02:50:05 PM »

absolutely awesome on that ammo box pic.that is a lot and i mean a lot of grinding to get those shapes with a 4 in grinder!ive made similiar stuff out of metal but always cut it to shape with a plasma cutter first.yu are a craftsman of the first order!

jpred1 · « **Reply #9 on:** April 03, 2010, 03:12:23 PM »

Killer job. Man ,Id like to have one of those. Gonna have to take a lttle time and start one. Kudos!!

Zulu · « **Reply #10 on:** April 03, 2010, 05:36:36 PM »

hillbill,
Thanks.
Craftsmanship has nothing to do with it. I don't have a plasma cutter.

I have to do it the old fashion way.
Zulu

Zulu · « **Reply #11 on:** April 04, 2010, 01:01:17 PM »

Got a little more metalwork done today. Four flat plates 1/4" thick for the handle bases. And all iron center punched, drilled, and countersunk for screws.
Still have to get some more flat bar and take my torches in for repair before I can do much more. I'll do that early this week if I'm not fishing.

Zulu

hillbill · « **Reply #12 on:** April 05, 2010, 03:45:27 PM »

what kind of primer and paint and preperation do yu use? i find metal that has been heated or welded very hard to keep paint on if its exposed to any moisture at all?

Zulu · « **Reply #13 on:** April 05, 2010, 05:08:06 PM »

I will take a wire brush on my grinder to it and clean it to bare metal. Then I just clearcoat it with clear laquer.
That's what I did on the original box.
Zulu

Zulu · « **Reply #14 on:** April 07, 2010, 12:59:51 PM »

I hope I'm not boring anyone with metalwork on a woodworking forum but it is all part of my ammunition box.
Worked on metal for about 7 hours today. It is dirty work but very rewarding if you take your time and try to do it right.
Worked on hinges first.

Made 2 cuts 1 1/2" long on the hinges.

Cut out the center piece of one hinge and the end pieces of the other hinge.

Ready to heat and bend

Bent it around 5/16" round bar.

Some custom bending to make them fit my chest lid and they are ready for cleaning.

Heat and bending 5/8" round bar for handles.

Ready for welding.

Finished, ready for cleaning.

Heated and bent to 90 degrees all corner braces.

Still have to make the hasp when I get some more iron. Maybe tomorrow.
Hope you enjoyed the pics.

Zulu

mechanic · « **Reply #15 on:** April 07, 2010, 01:12:33 PM »

Good work Zulu. If you ever want to part with that anvil let me know. I only have three. I would love to have a 1000# shop anvil I have located, but the guy wants my house, car and one of my legs.......

Ben

Zulu · « **Reply #16 on:** April 07, 2010, 01:56:33 PM »

I paid $350 for that 313 lb. anvil. I like it. I also have a 105 lb.
I can't imagine a 1000 lb.

Zulu

hillbill · « **Reply #17 on:** April 07, 2010, 03:55:28 PM »

love the way yu built them hinges, ill be makeing all mine from now on the same way.i honestly dont know how sum people live life without a torch and a welder.

Zulu · « **Reply #18 on:** April 13, 2010, 01:22:29 PM »

Got the material I needed to make the hasp. Made it and cleaned everything up. Ready for final fitting and then clearcoat. Have to laquer the chests too.
One set of hardware finished. Now to start the other one.
Zulu

Zulu · « **Reply #19 on:** May 04, 2010, 05:57:39 AM »

I finally finished the iron work for the second ammo chest. Here they are after laquer. There is about 50 hours of work there.
Now I am ready to laquer the oak chests. After that, assembly!

Zulu

mechanic · « **Reply #20 on:** May 04, 2010, 03:16:20 PM »

Truly works of art my friend...kudos to you!

Zulu · « **Reply #21 on:** May 04, 2010, 04:20:09 PM »

Thanks Mechanic,
I have had friends ask me why I would spend so much time making something I could buy. Right now I am making these for me. If I am lucky enough to sell them later that will be fine. Right now they are for me and you can't buy this stuff anywhere.
If I'm not making something for someone, I'm the only one I have to please.

Zulu

Zulu · « **Reply #22 on:** May 15, 2010, 08:30:56 AM »

Finally finished both ammo chests.

Each chest got 3 coats of clear laquer with no stain. Both got sliding walnut trays. Just finished assembly today.
Both will go on Craig's List soon. If anybody has any interest send me a personal message.
Enjoy the pics.
Zulu

Oldshooter · « **Reply #23 on:** May 20, 2010, 05:28:31 PM »

IMPRESSIVE Zulu!! You are an artisan! When you master Bassfishn you will be well on your way to imortality!

Thanks for the post!

Savage .250 · « **Reply #24 on:** May 21, 2010, 01:32:19 AM »

Having no talent when it comes to wood work or metal work, I can certainly appreciate what you have
created. You have talent my friend!

Next you need to "make" a weather vain to put on your roof in the shape of a ..........cat-fish!

I couldn`t pass that up.

Oldshooter · « **Reply #25 on:** May 21, 2010, 06:38:14 AM »

Did ya put em on craigs list yet? Are they on craigs list in Houston? I know some folk that are interested in some!

xo18thfa · « **Reply #26 on:** May 29, 2010, 09:12:42 AM »

Really nice work Zulu. That's a nice looking forge. Did you build that too?

Bob

Zulu · « **Reply #27 on:** May 30, 2010, 02:57:38 PM »

xo18thfa,
Did not build my forge. It is actually a horseshoe forge with two burners and a rear trap door for longer progects. I like it a lot.
Zulu

Alan R McDaniel Jr · « **Reply #28 on:** August 21, 2010, 04:37:47 PM »

I thought I was talking to somebody like me, just an average weekend woodworker. You're very good at this. I am in awe.

Alan

Zulu · « **Reply #29 on:** August 21, 2010, 05:04:46 PM »

Alan,
Thanks for the compliment.
I like doing a little bit of everything.
I am working on a 6' long bench now. It is warped, twisted and everything but flat. I like it that way.

It adds character.
Click on my web site at the bottom of my postings and you will see the wooden cannons I build. They are the coolest and are my specialty.
Zulu