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2010 National Jamboree

Patrol Box Construction

Oct 6, 2009

1st attempts at coming to a finalized design began. With the help of Paul Chemler, Ray Loback stepped up to help design and draw in Autocad our new Jamboree Patrol boxes. Ray and Paul and I went back and forth many times to get all in order. Throughout the entire process Bob Henderson was consulted many times for ideas and improvements to the patrol box plan due to his experience at a prior jamboree.

Thanks to Paul, Ray, and Bob for a great plan.

Feb 1, 2010

Finalized Patrol box plan and revised material list provided by Ray.

Click here for a copy of the Patrol Box Assembly plan

March 8th 2010

Material for 25 Patrol boxes

loaded on the trailer

My son Kevin with 25 patrol boxes

March 10th 2010

I delivered all the patrol box material to the Montalbano Majestic
Fine Furniture Factory today and unloaded it with the help of Rick Montalbano.

I worked with Giuseppe (Joe) for a few hours finalizing the design and taking his recommendations on construction and design. You have to understand, Giuseppe DeFrenza is a fine craftsman who has hand made some of the most prestigious furniture used around the world, by Kings and Presidents of Countries. I was very fortunate to have his time to be my mentor.

Giuseppe, an Italian born fine furniture maker has been hand making fine furniture for over 60 years. He is master wood carver and artisan.

Above right photo is a safety jig Giuseppe showed me how to use to eliminate slippage and kickback while making rabbet joints for the patrol boxes.

Here is Giuseppe passing on to me some

woodworking skills and secrets too.

Here I am with the Rolls Royce of panel saws. This high end Swiss made Striebig vertical panel saw (with accuracy to .004") is what I am using to cut the panels for the patrol boxes. Here I am about ready to put it to use. New, this machine sold for $50,000.00 (Fifty Thousand Dollars)

Rick Montalbano lending a hand with the panel saw.

Partial stack of precision cut material

March 11, 2010

Getting ready to make all the dado and rabbet joints

Making the cuts

Outside panels laid out ready for glue and fasteners

Gluing, Tacking & clamping

Giuseppe helping with some calculations

for the interior shelves and dividers.

March 15, 2010

Day started on the router, cutting all the carry handles

(above) Jig used to cut the handle holes

..............Only 46 more sides (handles) to cut

Next Step..............

Now it's on to some sanding of the handle holes on the spindle sander

March 16, 2010

Remainder of all the interior panels were cut today and test fitted into the patrol box.

With a last minute update to the plan, I discovered that it looks like we will be able to actually store the patrol box legs inside the box.

Basic patrol box minus rear top panel and doors

Now onto cutting the internal leg supports,

of course that means another jig

1st the lengths of 2 x 6 were cut

Then on to the boring machine

Completed Leg supports

March 18, 2010

Leg supports are cut from a 2 x 6 with a 31/32 hole drilled at a 15 degree angle. Two support were cut from each 2 x 6 then ripped on the rip saw (below). (probably the most dangerous tool in the shop)