boxes for bubs

**fletty** · 23rd June 2013, 08:38 PM

I'm still enjoying having already made most of the bits but, unfortunately, not all of them...
I started work on the trays for box 3 and 4 which started with reaching into the box ...

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and pulling out a full set of OUTER bits .....

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but none of the inner bits

so I milled up some more stock, cut the inner bits to length.......

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and cut all of the rebates on the router table using the router sled. The piece clamped to the back prevents the rebates from breaking out on the back

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In the meantime I glued the outer sides together using my new Bessey band clamp which has a huge benefit over my (otherwise) favourite FrameCo clamps in that the Bessey clamp's corners straddle the finger joints and put the pressure just where it is needed. The Duoklamp is being used as an adjustable spreader to stop the sides from bowing in.....

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After the box has set, I milled a rebate around the bottom edge to take the 3mm ply base which is first covered with suede. Milling the rebate after the sides are glued overcomes the problem of the rebate otherwise damaging the finger joint. I also leave a 'witness' mark to the vertical grooves because it helps tp locate the dividers from underneath when tacking the base in place

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I then dress the finger joints with my trusty low angle smoother which takes beautifully thin shavings from the ARC and easily slices across the grain on the fingers....

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to insert the dividers I turn the tray over so that its top surface is against the saw bench and then push the dividers in so that the bench top lines them up with the sides, a little drop of glue is placed in the rebate first....

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but, when you turn it over, it shows that the little drop of glue has travelled the whole length of the rebate to ensure a fully glued joint.....

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next I use a round over bit to radius all of the top edges....

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cut and fit the ply bases

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and, after checking the fit and finish sanding, I give it a good covering of fine buffing oil applied with steel wool... to which I give ... a fine buffing ........

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to be continued.......

**fletty** · 23rd June 2013, 08:54 PM

The picture frame which is hinged to the lid, requires a stop when the box is open to stop it from sliding too far forward and I achieve that with some huon pine buttons that I set into holes drilled with a forstner bit into the front of the tray. Rather nicely, the huon buttons come from the centres of the circular dividers in the box for elsa.......

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after the suede covered base has been fixed into the bottom of the tray via countersunk screws into the corner blocks, a piece of stiff felt is glued onto the bottom (of the bottom?) and the trays put into their boxes for an admiring look and a celebratory glass of shiraz....

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the boxes and the remainder of the shiraz are then taken inside to have the picture frame loosely propped in place ... and the bottle finished....

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the fourth baby hasn't been born yet so no pictures yet for box number 4 although I guess I could frame the ultrasounds.......... ?

fletty

**fletty** · 12th July 2013, 03:54 PM

The four bub boxes are all finished but I decided (= agreed) to fit engraved plaques with the bub's names and date of birth. I went to the local engraver, keycutter, locksmith and purveyor of Swiss Army knives in a stall at the local shopping mall (there's a limerick in there somewhere!) and I chose an elliptical polished brass plaque to be engraved. I was amazed at the quality of the computerised engraving, it was beautifully done.
I made up a matching template and router jig to rout a shallow recess which was a neat fit to the plaque and glued in only 3 of the plaques .... because the fourth bub hasn't been born yet and the name and sex are unknown to all but Mum and Dad.
Box 3 has been handed over with much ceremony and Boxes 1 and 2 were returned to me to fit the plaque.
It was a fun job, I couldn't have done 4 to the complexity of 'Elsa's box' but everyone is happy with these.
I wish i had used the stitched finger joints from Elsa's Box. I think the contrast of the ebony and Australian red cedar would have looked very good but, other than that, I am pretty pleased.

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My next job is something for ME. I'm going to recycle a 19th Century piece of Chinese furniture to a 21st Century role ... but make it reversible ......

thanks for all of the support

fletty