Sequence of Operations.

	CHECK MATERIAL.
1.1	Size -- Length, width and thickness.	Rule.
1.2	Deformation --Bend, twist and cupping.	Visual.
1.3	Knots - Live, dead or defective.	Visual.
1.4	Imperfections - Splits, tears or holes.	Visual.

	MARK OUT LONG SIDES.
2.1	Check cut ends for squareness. (Sand, file or recut if necessary)	Try square.
2.2	If square, mark cut ends with an arrow   >	Pencil.
2.3	Mark off 200 mm from each end.	Rule, pencil.
2.4	Draw line square.	Try square, pencil.
2.5	Mark scrap side with hatching lines.	Pencil.

	CUT LONG SIDES.
3.1	Cut off 2 lengths 200mm long. Cut on the scrap side. DO NOT CUT ON THE LINE	Tenon saw, bench hook.
3.2	Write your name on both pieces.	Pencil.

	MARK OUT SHORT SIDES.
4.1	Check cut ends for squareness. (Sand, file or recut if necessary)
4.2	If square, mark cut ends with an arrow   >	Pencil.
4.3	Mark off 85 mm from each end.	Rule, pencil.
4.4	Draw line square.	Try square, pencil.
4.5	Mark scrap side with hatching lines.	Pencil.

	CUT SHORT SIDES.
5.1	Cut off 2 lengths 85mm long. Cut on the scrap side. DO NOT CUT ON THE LINE	Tenon saw, bench hook.
5.2	Cut off upper groove on one end only.	Tenon saw.
5.3	Clean up saw cut.	File, glasspaper.
5.4	Write your name on both pieces.	Pencil.

	MARK OUT JOINTS.
6.1	Lay out all 4 sides in a line.
6.2	Mark adjacent joints with A-A B-B C-C D-D	Pencil.
6.3	Mark out joint thickness (11mm) on all ends.	Try square, marking out gauge.
6.4	Mark out joint width (15mm) on all ends.	Rule, pencil, marking out gauge.
6.5	Lay out 4 sides matching letters A-A B-B..
6.6	Mark out parts to cut out. (groove on long)	Pencil.

	CUT OUT JOINT ON LONG SIDES
7.1	Cut down both sides of the joint. DO NOT CUT ON THE LINE	Tenon saw.
7.2	Cut across the bottom of the joint.	Coping saw.

	CUT OUT JOINTS ON SHORT SIDES.
8.1	Lay out 4 sides matching letters. A-A B-B..
8.2	Check the marking out of joints on short sides against the cut joints of long sides and adjust where necessary.	Rule, pencil.
8.3	1st. cut down the grain. DO NOT CUT ON THE LINE	Tenon saw.
8.4	2nd. cut across the grain.	Tenon saw.

	CLEAN UP GROOVES.
9.1	Clean up grooves for lid.	Glasspaper, file.
9.2	Clean up rebate for base.	Chisel. Glasspaper.

	ADJUST JOINTS TO FIT.
10.1	Lay out 4 sides matching letters. A-A B-B.
10.2	Fit each joint together. Align bases. Square in all directions.	Chisel, Try square. File, glasspaper.
10.3	Adjust joints until sides parallel and correct dimensions 200 x 85 mm.	Rule.
10.4	Dry assemble 4 sides and secure with tape.	Masking tape.

	MARK OUT HARDBOARD BASE
11.1	Check material for quality and size.	Visual.
11.2	Check one long edge for straightness. Draw file or recut if necessary.	Straight edge or rule.
11.3	Mark long straight edge with a > mark.	Pencil.
11.4	Check one short edge square to long edge. Mark square line and draw file or recut.	Try square.
11.5	Mark short straight and square edge with a > mark.	Pencil.
11.6	Place hardboard base in rebate with long and straight edges in the rebate. (smooth side inside the box)
11.7	Mark point on hardboard where excess has to be cut off.	Pencil.
11.8	Repeat at other end and join points with a straight line.	Rule, pencil.
11.9	Repeat 11.6 to 11.8 for short edges.

	CUT & FIT HARDBOARD BASE.
12.1	Cut off excess material 1mm bigger.	Tenon saw, Bench hook.
12.2	File down one long and one short edge so that base just fits inside rebate groove.	File.
12.3	Clean up edges.	Glasspaper.

	GLUE UP SIDES & BASE.
13.1	Layout 4 sides flat around the base.
13.2	Glue up 1st. pair of joints.	Brush, PVA glue.
13.3	Glue up 3 remaining joints.	Brush, PVA glue.
13.4	Glue in base. (rough side outside)	Brush, PVA glue.
13.5	Wipe of excess glue on outside of joints.	Damp cloth or paper.
13.6	Tape up 4 sides for security.	Masking tape.
13.7	Check for squareness, size and parallel.	Try square, rule.
13.8	Glue in base.	Brush, PVA glue.
13.9	Wipe off excess glue.	Damp cloth or paper.
13.10	Tape up base for security.	Masking tape.
13.11	Wipe off excess glue from inside the box.	Damp cloth or paper.
13.12	Check again for squareness and size.	Try square, rule.
13.13	LEAVE BOX TO DRY FOR 24 HOURS.

	FINISH BOX.
14.1	Remove excess joint material	Chisel.
14.2	Rub down all surfaces.	Glasspaper, disc sander.
14.3	Fill holes.	Wood filler, Polyfiller, Filling knife.
14.4	Rub down. (refill if necessary)	Fine glasspaper.
14.5	Primer/sealer coat.	Thinned, varnish or paint, brush.
14.6	Rub down. (removes raised fibres)	Fine glasspaper.
14.7	1st. coat.	Varnish or paint, brush.
14.8	Lightly rub down.	Fine glasspaper.
14.9	Top coat.	Varnish or paint, brush.
14.5	Polish.	Cloth.

	MARK OUT LID LONG SIDES.
15.1	Check material for quality and size.	Visual.
15.2	Check one long edge for straightness. Draws file or recut if necessary.	Straight edge or rule.
15.3	Mark long straight edge with a > mark.	Marker pen.
15.4	Check one short edge square to long edge. Mark square line and draw file or recut.	Try square.
15.5	Mark short and square edge with > mark.	Marker pen.
15.6	Insert the lid with long and straight edge in the groove.
15.7	Mark points on lid where excess has to be cut off.	Marker pen.

	CUT LID LONG SIDE.
16.1	Cut off excess material 1mm bigger.	Tenon saw/hacksaw, Bench hook.
16.2	Draw file down one long edge so that lid just fits inside groove.	File.
16.3	Clean up edges.	Wet 'n' dry paper.

	MARK OUT LID TO LENGTH.
17.1	Insert lid and mark off length.	Marker pen.

	CUT LID TO LENGTH.
18.1	Cut off excess material 1mm bigger.	Tenon saw/hacksaw, Bench hook.
18.2	Draw file down to length.	File.
18.3	Clean up edges.	Wet 'n' dry paper.

	MARK OUT FINGER HOLE.
19.1	Draw centre line along length. (hole end)	Marker pen, rule.
19.2	Draw centre line of hole 25 mm from outside edge of box	Marker pen, rule, try square.

	DRILL FINGER HOLE.
20.1	Drill 3 mm diameter hole.	Pillar drill, drilling jig, 3, 6, 10 mm drill bits.
20.2	Drill 6 mm diameter hole.
20.3	Drill 10 mm diameter hole.
20.4	Clean up hole both sides.	Large drill, round file, wet'n'dry.

	ASSEMBLE & TEST.
21.1	Fit lid and check for free movement. Draw file if necessary.	File.
21.2	Polish lid sides.	Perspex polish.
21.3	Remove protective plastic covering.
21.4	Test with pencils, pens etc.	Range of products.
21.5	Evaluate your pencil case against others.	Questionnaire.
21.6	Write your evaluation.	Evaluation sheet.