Bullet Boards 2 of 2

The camera angle did not show the bottom line on the bottom board but each piece was laid out 1/8 inch wider and longer then the size of the bullet board so it could be sanded flush when it was assembled. 

Below is 5/8 inch wire brads and long nosed pliers. You do not need a wire brad gun to make such assemblies. I have a air brad gun but the process below will allow you to assemble such a project without one. To many people buy tools that they will uses so seldom as not to pay for the investment. 

Long nosed pliers are used with a piece of rag to stain the inside of the holes. This would be very difficult  with the part assembled so do this first. Note the exit holes where the drill bit came out facing you show some splintered aeries these will be hidden. If you ever need a hole clean with no splinters on each side clamp a scrap board to the drill press.  

A drop of glue is placed strategically and the the 1/4 inch bottom was already stained and placed so as to hang over the edges. 

Below is the assembly of the bottom with wire brads around the edges. 

With the bottom assembled it is then sanded flush with the oak board to give the job a flush fit. Note the edges are given a slight touch to get rid of the sharp corners on the board itself as well as the 1/4 inch bottom. I turned the board in a 45 degree angle to accomplish this. I did this with the electric sander below but you may want to do the job with a sanding block as you could make a mess out of it if you goof. It takes a quick light touch if using the electric belt sander.

The bullet boards are given one last stain and allowed to dry for a day and will be ready for your choice of polyurethane, varnish, or lacquer. If this is the first visit to the sight the bullet boards are leaning against a home made 90 lb lead melting pot that I show how to build on this blog made out of scrap iron. 

 Richard W Norman the Junk Ologist

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