Thread: Starburst - segmented box - Northern Silky Oak/Silver Ash - WIP

Top tray ready for assembly
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Lid separated
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Hinge holes drilled
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With tray sitting in. A few dividers to go in yet, just meet to set them out
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Next will be to bevel the back edge for opening, final sanding before finishing.

Really spectacular and looking forward to seeing the completed item.
Which method did you use to separate the lid from the box?

Originally Posted by Treecycle

Really spectacular and looking forward to seeing the completed item.
Which method did you use to separate the lid from the box?

Thank you. I can't wait to finish either so I can get back to a doing some turning.

i use a 1.6mm thick slot cutter on the router. And I then place a 3mm sheet of mdf in front of the cutter so that as it breaks through it creates a zero clearance and prevents tear out. I also follow the box through with a block to prevent tear out at the ends. And luckily the bearing at the bottom of the cutter shaft leaves just enough room 9 or 10 mm I think so that you don't go all the way through. I leave 0.5 -1mm meat to finish with a flush saw.

i am in the process of making a jig/guide so that you can put it either side of the slot and stop the saw blade from wandering into the freshly cut slot. pictures will be posted when finished.

I was looking at a slot cutter at the Carbitool stand at the Wood Show last weekend. They had one that was 1.2mm wide but it doesn't appear in the catalogue so I don't know if it is a new size they have introduced. I was thinking it would be ideal for separating the lid and should have brought one then.
Keen to see your jig when you have it completed.

Originally Posted by Fumbler

Thank you. I can't wait to finish either so I can get back to a doing some turning.

Better get into the shed with the lathe quickly, and lock the door. I think you’re going to have a long line of friends and family wanting a beautiful box like this.

Originally Posted by homey

Better get into the shed with the lathe quickly, and lock the door. I think you’re going to have a long line of friends and family wanting a beautiful box like this.

Too right. I have a nice piece of figured blackbutt just itching to be vased!!

Angle now routed into the back, hinges loose fitted, and tray set out. No pic of routered angle I'm afraid. A bit later. Small tearout (luckily on back corner and was able to glue back the piece) as I had put a block behind whilst testing and it was bigger than needed so I trimmed the fence and stupidly used the same block so it just took the corner out.

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I did however notice that the lid looks spectacular open also so I don't think I will cover with suede, my only issue is it's not sanded well enough plus there's glue showing in the very corners. So I have to figure out a way to clean up and sand properly whilst in its current state. Bit of a job, and I don't want to glue some edging in for fear of warping.

does CA glue have the same effect? If I was to put some beveled edging around the lip and spot glued with CA, will this warp the lid? Any help would be appreciated.

Final stages coming together very nicely. All your WIP is very helpful for us newbies especially all the little problems you have dealt with along the way.
A question about your tray dividers. Are the segments just butt joined or is there some other joinery that can't be seen?

Originally Posted by Treecycle

Final stages coming together very nicely. All your WIP is very helpful for us newbies especially all the little problems you have dealt with along the way.
A question about your tray dividers. Are the segments just butt joined or is there some other joinery that can't be seen?

Thank you, no they are straight butt joins, glued in. I sort of tend to do things on the fly and change them as I go. It allows me to correct things more easily.

A few more updated photos and a sneak peek at what the finished top will look like.

so splines cut of and sanded.
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Now I know that a-se beats class every time, But i have managed to pull a rabbit out of the hat on this one. The original price of timber was 20mm thick and sliced through the band saw, to 12mm giving me some wiggle room for thicknessing and sanding for final sizing, the offcut strip I have used for the tray and tray supports, and if u look closely the rabbit I pulled out is that I have matched the grain pattern right through.
1. Tray rails
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2. Tray
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Here are some bevel pics I took the 45deg past the centre line so that I got a greater than 90 degree opening and no need for stays.
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As noted yesterday, the lid is too beautiful to cover with suede, and I was concerned that it wasn't sanded fine enough, so I got the renovater tool out and put the sanding pad on and gave it a skin with 120/180/240 then 400 and is now looking a treat. The glue lines should in fact be now not so visible as the finish will darken the timber enough to hide.

but here is the top of the box wiped over with metho to show closely what the finished product will look like. And I have to say, its mesmerising.

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Now I just have to cut up the card for the tray liners and cover. Then do final finish.

Starting onbthe finishing stages. Felt linings done, although the square on the left is supposed to be ring holders, so will recover that.

ive chosen Kunos Livos oil as the finish. Bit my first choice of colour but the recipients husband said blue and it was the best looking blue I could find.

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And 1st coat
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the blue tape protects the base from the finish as nothing sticks to waxed oil so it gives the double sided tape something to stick to. Found that out the hard way on a previous box.

Looking spectacularly awesome - thanks for the detailed WIP and clever ideas along the way !

That is a stunning box. Gees, I wouldn't like to have to give it away after all of that work. Hope the recipient really appreciates the work you have put into it. Maybe give them a printout of this whole thread for prosperity.

Coming along very nicely indeed.

Alan...

Oooh, look at that! My 1000th post. You should feel honoured!

Originally Posted by Uncle Al

That is a stunning box. Gees, I wouldn't like to have to give it away after all of that work. Hope the recipient really appreciates the work you have put into it. Maybe give them a printout of this whole thread for prosperity.

Coming along very nicely indeed.

Alan...

Oooh, look at that! My 1000th post. You should feel honoured!

Thank you and yes well done on the 1k posts!!

i do have the off cuts from the wedges so I will definitely be making anothe one the same for my daughter. I'm sure it will be well received and yes I had thought about keeping it, but I couldn't, I wouldn't feel right.