School of Arts and Sciences (NSW/ACT)

TECH307 Design & Technology Internship

OPERATION SHEET
Student Name: Michael Di Mauro S00165601
Date: 24/10/2016
Component Name: Tea Box
Material / Size: Timber (Silky Oak / New Guinea Rosewood)
Operation

Name of

Machine

Cutting

Depth of

Number

operation

Tool

Tool/s

Cut

Mark timber

Ruler
Try-square
Pencil

10

20

30

40

50

60

70

Cut timber
lengths

Radial Arm
Saw

Feed

Remarks

Mark all timber to length using a ruler, try-square and

pencil.

Through

3,400rpm

Hand

Cut the timber lengths with care using the radial arm
saw, avoid having fingers / hands close to the blade.

Ruler
Try-square
Pencil

Mark mitre
joints

Cut mitre
joints

Radial Arm
Saw

Ruler
Try-square
Pencil

Mark inserts
on sides of
box

Speed

Using a try-square and ruler mark the mitre joint with

the cut being 19mm from the end (thickness of timber).

Through

3,400rpm

Using the radial arm saw on a 45 angle cut the mitre

joint.
Measure and mark the inserts with a ruler, try-square

and pencil for the drawer and dividers to sit on.

Using the table saw with 5mm of the blade showing cut

Cut bottom
and divider
slits for inserts

Table Saw

Cut drawer

Table Saw

Michael Di Mauro S00165601

5mm

4,000rpm

Hand

the guides for the inserts to be later glued into.

Using the table saw with 5mm of the blade showing cut

runner slits for

inserts
80

85

90

100

5mm

Mark drawer
housing on
front
Pilot hole for
drawer
housing
Jigsaw drawer
housing
Rout drawer
housing

Ruler
Try-square
Pencil

4,000rpm

Hand

the guides for the drawer runners to be later glued into.

Using a ruler, try-square and pencil the 40mm drawer

front was marked out on the front face of the box.

A 10mm hole was cut in each corner of the marked

Electric
Drill

Hand

drawer housing to be then cut with the jigsaw.

A jigsaw was used to remove majority of the waste for

Jigsaw

Through

Hand

the drawer housing.

Using the router with a straight bit cutter the drawer

Router

Through

23,000rpm

Hand

110

housing was cut following a clamped guide.

A Chisel was used to clean up the corners and edges of

Clean up
housing

Chisel

Through

Hand

Hand

the cut out where the router couldnt reach to make a

perfect rectangular housing.

120
Mark box feet

Ruler
Combination
square
Pencil

A pencil, ruler and combination-square was used to

-

130

mark the 45 angled feet

A guide was set in place to cut the feet after it was

Cut box feet

Router

Through

23,000rpm

Hand

135

marked out.
With the router not being able to cut the corners and

Clean up box

Chisel

Through

Hand

feet

the 45 angle a chisel was used to cleanly cut the

marked feet.

140

A dry assembly was used to ensure everything fit well

Dry assembly
of carcass

Michael Di Mauro S00165601

and correctly before it was to be glued up.

-

145

Glue carcass

box clamps and PVA 101 wood glue.

together
150

Mark lid
-

160

170

180

Cut lid

The carcass of the box, with the inserts was glued using

Ruler
Try-square
Pencil

The lid was marked out using a try-square, ruler and

Radial Arm

pencil ready to be cut.

The radial arm saw was used to cut the lid to size.

Saw

lid

Ruler
Try-square
Pencil

of the lid was marked out.

Cut Inlay

Router

5mm

23,000rpm

Hand

A router was then used along with a straight guide to

Mark inlay on

3,400rpm

Hand
Using a ruler, try-square and pencil the inlay on the top

cut the rectangular inlay.

190

Clean cut

Chisel

5mm

Hand

Using a chisel the corners of the cut were cleaned up to

make a perfect rectangular recessed hole.

195

Glue inlay

Using PVA 101 wood glue and an f clamp the inlay was
glue into the top with excess glue wiped off with a wet
rag.

200

Lid profile

Router

10mm

23,000rpm

Hand

With a chamfer bit the lid was profiled 10mm from the
top.

210

220

Mark dividers

Mark cross
halving joint

Michael Di Mauro S00165601

Ruler
Try-square
Pencil
Ruler
Try-square
Pencil

Dividers were marked using a ruler, try-square and a

pencil to length.
The cross halving joints were marked to half the timbers

width (20mm) using a pencil, ruler and try-square.

230

240

The radial arm saw was used to cut the interlocking

Cut cross

Radial Arm

halving joint

saw

Cut dividers

Radial Arm
Saw

3,400rpm

Hand

3,400rpm
-

joints.

After the cross halving joints were cut the radial arm
Hand

saw was used to cut the pieces to length to fit into the
box.

250

260

Mark handles

Cut handles

Ruler
Try-square
Pencil
Tennon Saw

Two wooden handles were marked using a ruler, trysquare and a pencil.

10mm

Hand

The handles and the overhang were cut using the

tennon saw.

270

Clean up cut

Chisel

Hand

The cuts were cleaned up with a chisel, removing the

rough sawn cut marks.

280

Sand Handles

Sandpaper

Hand

Sanding block
290

Mark drawer

sides + front
300

310

Cut drawer

Radial Arm

sides + front

Saw

Mark box pin

joints
320

Cut box pin

joints

Michael Di Mauro S00165601

Ruler
Try-square
Pencil
-

Both handles were then sanded from 150-400 grit

sandpaper.

The drawer was marked out using a pencil, try-square

and ruler to fit the housing made on the box.

3,400rpm

Hand

The length of timber was then cut using the radial arm
saw into pieces.

Ruler
Try-square
Pencil
Tennon Saw

Box pin joints were marked on all pieces of the box

(minus the front) using a pencil, ruler and try-square.

Hand

A tennon saw was used and the pins were cut by hand
in a bench vice.

330

Clean up

Chisel

Hand

joints

With the joints cut a chisel was used to clean each joint
and make sure they were tight and snug not loose
fitting.

340

Mark rebate

for drawer
bottom
350

Cut rebate

Table

Ruler
Try-square
Pencil
-

rebate which would hold the drawer bottom.

5mm

23,000rpm

Hand

Router
360

Mark drawer

bottom
370

380

Cut drawer

Radial Arm

bottom

Saw

Dry assembly

Ruler
Try-square
Pencil

410

A pencil, ruler and try-square were used to mark the

drawer bottom to length to fit into the rebate.

Through

3,400rpm

Hand

The bottom was cut using the radial arm saw to size.

A dry assembly was used to ensure everything fit well

and correctly before it was to be glued up.

Glue drawer

together
400

A table router was used with a straight bit cutter to cut

the rebate 5mm for the drawer bottom to fit.

drawer
390

A pencil, ruler and try-square was used to mark the

Box Clamps

F Clamps

Sand entire

Orbital

150-400 grit

box

Sander

sandpaper

Glue drawer

Epoxy 2 pt

handle

The drawer was glued using box clamps and PVA 101
wood glue. A wet rag was used to clean up excess glue.

The entire box was then sanded from 150-400 grit

sandpaper.

glue

The drawer was too small for the handle to be screwed

into so a 2 part epoxy was used to attach the two
together.

420

Mark hinge
recess

Michael Di Mauro S00165601

Ruler
Try-square
Pencil

The hinges were used to create a marking on the

underside of the lid and the box with a pencil and trysquare.

430

Cut hinge

Router

2mm

23,000rpm

Hand

recess
440

A trim router was used and a recess was cut to 2mm by

hand.

Clean up cut

Chisel

Hand

A chisel was then used to clean up the recess and make

it square.

450

Mark pilot

hole for
screws

460

Cut pilot hole

Electric

Punch
Hammer
Ruler
Try-square
Pencil
-

hinges were to be screwed on the lid and box

5mm

2,000rpm

Hand

Drill
470

Mark pilot

hole

480

Cut pilot hole

Electric

for top handle

Drill

A punch was used to start the pilot hole where the

An electric drill was used with a 2mm bit to cut the hole
for the screws to be driven in avoiding splits or cracks.

Punch
Hammer
Ruler
Try-square
Pencil
-

A punch was used to start the pilot hole where the

hinges were to be screwed on the box.

5mm

2,000rpm

Hand

An electric drill was used with a 4mm bit to cut the hole
for the screw to be driven into the handle avoiding splits
or cracks in the lid

490

500

510

Countersink

Electric

pilot hole

Drill

Screw top

Electric

handle

Drill

Final sand

2,000rpm

Hand

end up being flush with the timber and not raised.

-

2,000rpm

Hand

Lacquer mixed

Michael Di Mauro S00165601

The top handle was screwed and glued using PVA 101
wood glue.

400 Grit

Hand

sandpaper
515

The pilot hole was countersunk to allow for a screw to

The box was given a final sand to remove any stains or

impurities.

Hand

The lacquer was mixed into the spray gun with 400ml of

Acid Cat 100% gloss lacquer, 200ml of thinners and

100ml of hardener.
520

Apply first

Air

Hand

The first coat was applied to the entire box and left to

lacquer coat

Compresso

dry for 45mins until fully cured (faster drying time with

r + Spray

acid cat lacquer and hardener).

Gun
530

Sand after

coat dries
540

400 grit

Hand

sandpaper

Apply 2nd & 3rd

Air

coat

Compresso

Light sanding was given after the first coat was cured
with 400 grit sandpaper.

Hand

The 2nd and 3rd coat was applied after one another once
each was completely dried with the spray gun.

r + Spray
Gun
550

Lid attached

Electric

to box

Drill

Michael Di Mauro S00165601

2,000rpm

Hand

The hinges were screwed into the lid and to the box
attaching the two pieces once the lacquer was cured.