Gerstner J1001 Just Right Box Instruction Manual

Table of Contents

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prep parts and Work Area before starting

Make sure you are working on a sturdy, flat work surface that will not scratch or damage the parts while handling.
Lightly sand and deburr the part edges if needed.
It is recommended to dry fit (construct without glue) the parts to familiarize yourself with the assembly process.

Recommended Tools for Chest Construction

I t is important that you prep the parts for assembly. Deburr all parts and inspect grooves for “chip out.” “Chip out,” or splinters in the groove, will keep the parts from joining properly.

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The sides, front rail and back have been marked with matching indicators to ensure the proper orientation of parts. They could be lettered pairs or number pairs.
Glue the maple drawer slides into the sides, making sure that they are positioned all the way forward in the groove. Any gap should be to the back of the chest.
Make sure any excess glue is removed so it does not interfere with the function of the drawer.

Locate all parts for the top and lay them out in the way they will be assembled. Check orientation of the parts as they relate to the right and left sides.
Apply glue to both the shoulders and grooves of the top parts
Assemble the parts and clamp together.
Always wipe excess glue from the parts after assembly.

Drawer Assembly

Apply glue to the sides as shown
Install the drawer front and drawer back. Make sure the drawer bottom grooves are in alignment.
Slide the drawer bottom into place and install the remaining drawer side.
Make sure all parts are flush to the top edge then clamp drawer for proper assembly. Check drawer for square.

Sanding

17 Fill any open joints or imperfections with the quality wood filler of your choice.
Sand the surfaces flush using your preferred method. An orbital sander will greatly reduce the amount of work required. We sand chests with 120-150 grit paper before applying the stain and finish
OPTIONAL: Gerstner typically rounds over exterior edges to soften the feel of the product. This can be achieved with a 3/16″ Round over bit.
Sand and fit the drawer to the chest. Make sure it operates freely and has the minimal amount of gap. The minimum gap is 1/32’’. We recommend between 1/32-1/16’’

With the chest and top laying on their front faces, locate the hinge so it is 1-1/8″ from the outside edge and centered on the cutoff
Mark the position of the hinge screws.
Drill all the hardware screw holes with a 3/32’’ drill bit(excluding the top lid tack).
Carefully flip chest and top over so that the front of the box is facing upwards. To locate and drill for the lock, the lock will need to be positioned on the centerline of the chest. It might be helpful to start with the lower half of the lock and screw it down first. Then position the top half of the lock and drill for the screws. Screwing the bottom half helps keep things in position, reducing the chance of error

Drilling for Hardware (continued

Locate the rubber bumpers and position the holes ½’’ in from the outer edge of the chest.
Locate and mark the center of the drawer front. Drill a 3/16″ hole for the knob
Prior to finishing, remove any hardware that was installed during drilling. Lightly re-sand the exterior surfaces to remove any scratches or contamination
(oils from your skin). This will allow for a quality finish

Staining & Finishing

Many options exist for adding a protective finish to your wood project. Select the finish of your choice and apply as desired. If using the recommended Gerstner Classic Wood Stains with lacquer top coat, please follow the directions listed below.
Apply stain to inside edges, and exterior surfaces as desired. Wipe excess stain from the surface and make sure the color has been evenly applied
Apply a lacquer finish to the chest. Lightly sand the first coat, or seal coat, once dry with 320 grit sand paper.
Apply top coat to parts as desired and let finish fully cure before handling.

Hardware Installation

Locate the plunger pin, spring and 2 stainless steel
Position chest upright and place one of the stainless steel washers over the bottom hole in the front rail.
Using a pair of needle nose pliers, push the end of the pin through the bottom washer and release it through the top hole. This can be a bit awkward and challenging so attempts might be necessary. Scan the QR code above to see a video of this process
Install the chest hardware. DO NOT over-tighten the screws or you will damage the hardware. Drive the screw in until it makes contact with the hardware and stop
Close the top lid and carefully strike the plunger pin as to make a noticeable mark in the top. This will serve as the location for the steel tack.
Locate the tack mark made in the top and hammer tack into the rail. Make sure the top is being supported on the workbench as not to bend the hinges.
Install the Gerstner nameplate where desired. We typically place the nameplate on the top for this style of chest. After installation, remove the protective
film to expose the beauty and luster of the nameplate

A 50/50 mix of white glue and water can be used for felt installation. We recommend Gerstner Whew Glue for all felt applications, as it holds reliably, yet easy to replace if you ever need to re-felt in the coming years. It is the only felt glue we use in our workshop
Install large flat sections of felt first.
The surround strips are installed one at a time and will overlap in the corners.
After all felt has been installed, let the chest sit open for a few hours to dry.
Congratulations!
- You have built an heirloom quality Gerstner chest that will last for generations. Keep your fine wood chest in tip top shape by using Gerstner Finish Restorer and Preserver
- Scan to watch a brief video demonstration of cleaning with Gerstner Finish Restorer and Preserver
Did you Enjoy BUILDING YOUR NEW JUST RIGHT BOX?
- Check out all of the other Gerstner Workshop DIY Kits at www.GerstnerUSA.com

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