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4th May 2014, 06:32 PM #16SENIOR MEMBER
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WIP - Trio of Boxes Part 5
Next step is to add the splines to reinforce the mitre joins. A simple MDF jig and the table saw fitted with the square cut blade make this safe, repeatable and accurate. The spacing includes an allowance for the kerf that will be cut when the lid is separated from the base later.
Img 23 Spline cutting jig.jpg
The boxes have been sanded to 320 grit, and are ready for the keys to be glued in.
Img 24 Splines all cut.jpg
I really loved this box, and the way Andy had made a real highlight of the keys, so I'm going to copy it! The keys are built up of 5 layers of veneer, with a light colour on the outer surfaces with darker veneer in the middle 3 layers. Here are the veneers with plenty of glue, ready for clamping.
Img 25 Laminating veneers to make highlight.jpg
A couple of pieces of scrap melamine chipboard make an excellent disposable clamp. The glue won't stick to it.
Img 26 - Veneer press.jpg
After trimming the edges, I mark out the keys, using both edges to maximise stock usage.
Img 27 Marking out after trimming long edges.jpg
Keys are cut on the bandsaw, and are ready for a very light sand. I use the same sanding board shown previously, and it only takes about 4 "swipes" on each surface to make the keys the right thickness.
Img 28 Cut the keys on the bandsaw.jpg
Keys are glued in, and excess squeeze-out wiped away. I've decided to use these laminated keys on two boxes, and solid timber keys on the blackwood box. The blackwood box is made using PU glue, and I don't know how the different glues would interact, so best to stay with a solid timber key for the blackwood this time.
Img 28 Glue keys in place.jpg
Next steps are to use a flush-trim saw to take the bulk of the waste away, and then sand/scrape everything flat. That will have to wait until next weekend. Work is about to interfere with my hobby again...
Comments welcome.
cheers,
ajw
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4th May 2014 06:32 PM # ADSGoogle Adsense Advertisement
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4th May 2014, 07:24 PM #17GOLD MEMBER
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- Mar 2009
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- Sydney
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Looking good mate. What finish are you planning to use?
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4th May 2014, 07:47 PM #18
thanks for the journey
learning stuff is goodregards
Nick
veni, vidi, tornavi
Without wood it's just ...
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4th May 2014, 08:05 PM #19SENIOR MEMBER
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4th May 2014, 09:29 PM #20GOLD MEMBER
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It's going good. I'm just building some storage cabinets at the moment. My dusty has stopped working which slowed me up a bit but I'm getting there. I got a long list of projects to build so hopefully in the next 6 weeks I can start.
I look forward to seeing your boxes finished. Who's the lucky recipients?
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11th May 2014, 05:54 PM #21SENIOR MEMBER
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- Jun 2007
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- Blue Mountains
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WIP - Trio of Boxes Part 6
On the home stretch now.
Trimmed the mitre keys and sanded them flush. A couple hadn't seated fully, so I recut them and did them again. After sanding, I applied a coat of WOP. Photo show the wet finish looking very glossy.
Img 29 Mitre keys sanded and a coat of WOP.jpg
Next comes separating the lid. I use blue tape to help prevent any tearout.
Img 30 Cutting off the lid.jpg
To prevent the lid from collapsing into the sawblade, I use a packing piece to keep the gap open. Tape holds it in place.
Img 31 Packing out to prevent blade getting jammed.jpg
The PU glue on the blackwood foams a bit, and left a mess inside the box. Hopefully the finish I applied before glueup will make this easy to remove. Next time I will use tape to mask the area if I'm using PU glue.
Img 32 PU glue squeezeout on interior.jpg
Lids separated, and a very small chamfer applied to create a shadow line.
Img 33 Lids separated.jpg
I will be using SmartHinges on these boxes, but that will have to wait until next weekend. In the mean time, I'll start building up the finish.
I hope somebody is getting some use out of this WIP. Comments welcome!
cheers,
ajw
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11th May 2014, 06:24 PM #22
Beautiful Jewellery Box
AjW
That is a beautiful jewellery box.
Many thanks for this WIP. My wife has asked me to make a jewellery box for her mothers 80th birthday this december and I have learnt so much from your work in progress.
Much appreciated
Cheers
Woody1
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11th May 2014, 07:18 PM #23GOLD MEMBER
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I like the look of the WOP. I might give it a try some time.
I'm a big fan of the smart hinges also - simple to install yet very classy.
You've done well on the boxes. Nice choice of timbers too!
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11th May 2014, 08:23 PM #24Senior Member
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- Oct 2013
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- East Ballina
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- 195
Thanks AJW
AJW,
Definitely getting ALOT out of this WOP. As you know I am a new woodworker and have started with boxes. I often post here and your replies are always welcome.
I love the sanding block idea, its great to see how you do the lids and I also love the idea of a spacer and blue tape when taking the lid off to prevent tear out and the lid collapsing in on itself.
So in answer to one of your above posts- defintely learning a lot and getting a lot of out of this wop.
Really appreciate your time and sharing of technique.
Cheers
Andrew
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11th May 2014, 08:39 PM #25SENIOR MEMBER
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- Jun 2007
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- Blue Mountains
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Hellofellow, thanks for the kind feedback. Boxes are fun to make, but can be much more difficult to complete than people imagine. Even small errors seem to be magnified on boxes, and if your woodworking journey is anything like mine, you will wonder if you'll ever get one to be "perfect".
All three of these boxes have minor issues to my eye. Woodworkers will spot them, but others won't see any defects hopefully!
keep at it, and keep asking questions. This forum is a fantastic resource.
cheers,
ajw
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12th May 2014, 02:46 AM #26GOLD MEMBER
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- Apr 2011
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- McBride BC Canada
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- 3,543
Beauty is in the eye of the beholder (that's me.)
Thank you for such a richly illustrated lecture series on box making.
I can't get past an umbrella stand that's pegged together!
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12th May 2014, 09:51 AM #27
Trio of Boxes
Ajw
May I ask what is the thickness of the sides and Lid. What is the height of the lid when cut off.
Thank you
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12th May 2014, 10:38 AM #28
Very true words!
I cant remember a single thing that I have ever made where there has not been at least one small thing that I am not too happy with. But the recipients either arent as picky as I am about my work or are just too appreciative and polite to point it out.
I have been following your WIP as I too , make boxes in batches and have always found that you save so much on setup doing it that way, even with Incra gear which allows you to re-position the fences exactly to a predetermined setting.
But as Skew said, you can just as easily repeat the mistakes as the accurate cuts.
Looking forward to the rest of your WIP.
Cheers
DougI got sick of sitting around doing nothing - so I took up meditation.
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9th June 2014, 09:46 PM #29SENIOR MEMBER
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Trio of Boxes - Final Steps
After a bit of a break, I got back into the garage and fitted the hinges. I use a router to cut the hinge recess. I've used the SmartHinge, which opens to around 95 degrees and holds the lid upright. I use a spacer and stopblock to get the length of the recess right. The other important dimensions are the distance from the router fence, and the height of the router bit. I use scrap pieces to ensure it's spot on. Care at this step makes fitting the hinge much easier.
Img 34 Setup for hinges.jpg
A dry-fit of the hinges is completed. to ensure the lids fit squarely and that the lid closes fully.
Img 35 Hinge test fit.jpg
The holes for the screws are drilled, and then tapped using a steel screw. The brass screws are very soft, and I find using a steel screw with the same thread pattern makes the installation of the brass screws much easier. I learnt this the hard way...
Img 36 Steel screw.jpg
Hinges fitted, and screws in place.
Img 37 Hinge fitted.jpg
I just love the combination of Blackwood and Sassy.
Img 39 Blackwood and Sassy.jpg
Final step is to put the lining into the bottom of the boxes, and to apply wax and buff.
I've enjoyed making these boxes, and have identified recipients for each of them. At the start of this process, I wondered how much more efficient it would be making 3 rather than 1. Intuitively, I knew it would be more efficient, but I was surprised how much time I actually spend in setting up each step. The actual cutting and assembly doesn't take that much time, so making 3 didn't take all that much longer. I'm not sure I'd want to make 10 at a time, but when I'm next in the mood to make a box, I think I'll do the same and make 3.
Thanks for following along. Comments welcome, as usual.
cheers,
ajw
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11th June 2014, 04:43 PM #30
Well done, a quality WIP.
Thanks very much for a beautiful WIP.
I agree, I tend to make 3 boxes at a time now, only because it increases the production rate.
I also like the lid assembly method.
regardsBilly
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