Bigger Boxes

[my63]

Hi I am starting this new topic to share my adventures in box making with you.

I have been using the writing slope dilemma topic to share all of my boxes and I will return to that topic later in the year with more writing slopes.

I was asked by fpn member alc3261 to make a box to fit a space on her desk.

I have not made a large box before and I am not a professional woodworker nor do I have any sort of workshop.

 

To start I laid out the dimensions on a board in tape so i could see what I had to play with,

 

http://farm9.staticflickr.com/8239/8665372876_6ccb67830c_z.jpg

IMG_9797 by my0771, on Flickr

 

I cut the 25mm oak to size and mitred the ends with a bench sander I laid out the four pieces end to end and used masking tape to support the joints. I added glue to the joints and floded it up the tape acting like a hinge.

I used a strap clamp to pull everything together.

I added the walnut outer trim at this point top and bottom.

 

http://farm9.staticflickr.com/8240/8664260645_c7e1587276_z.jpg

IMG_9821 by my0771, on Flickr

 

When the glue was dry I made cardboard templates top and bottom I will return to these later.

 

I made a lid and base from 6mm marine plywood then veneered the top with Brazillian walnut.

 

http://farm9.staticflickr.com/8244/8664261729_ff82bee981_z.jpg

IMG_9873 by my0771, on Flickr

 

http://farm9.staticflickr.com/8260/8665363496_6ffe177f01_z.jpg

IMG_9883 by my0771, on Flickr

 

The next stage is to cut the lid from the box this is the stage where you can ruin all the work already done.

I cut the box by hand as I dont have a table saw.

 

Trays were next I set up my outside bench with a cutting block and some blocks to act as stops.

I cut all of the pieces in one afternoon.

Back to the bench sander to mitre all of the ends.

 

Again I used tape to support the joints while the glue set.

 

http://farm9.staticflickr.com/8243/8664302999_a8178d506f_z.jpg

IMG_9903 by my0771, on Flickr

 

The next stage was to fit a plywood base to the tray and add a divider for the smaller pens

 

http://farm9.staticflickr.com/8257/8664263177_aac6ca10f3_z.jpg

IMG_9916 by my0771, on Flickr

 

After checking with experts on a woodworking forum I cut some slots in the mitres to add splines for strength at this point I also added rare earth magnets to act a closure mechanism.

 

http://farm9.staticflickr.com/8253/8665366084_0531b158fc_z.jpg

IMG_0176 by my0771, on Flickr

 

http://farm9.staticflickr.com/8258/8664266011_b3c8355f50_z.jpg

IMG_0214 by my0771, on Flickr

 

I then veneered over these items in oak to hide them and added some gold plated hinges.

 

http://farm9.staticflickr.com/8258/8665368172_5bf72dafc9_z.jpg

IMG_0260 by my0771, on Flickr

 

Tray inserts were the next job

 

http://farm9.staticflickr.com/8262/8665368424_2083c6569a_z.jpg

IMG_3342_1 by my0771, on Flickr

 

Quite simple dowels glued to card as there are two sides to each tray both inserts need to match.

 

like this

 

http://farm9.staticflickr.com/8242/8665369012_ae8ba5c231_z.jpg

IMG_3388 by my0771, on Flickr

 

Covered in cobalt blue suede.

 

http://farm9.staticflickr.com/8264/8665369392_2bf01a1b8e_z.jpg

IMG_3390 by my0771, on Flickr

 

I cut four pieces of card to fit the inside of the box, I held them in place and used tape to fix them together then removed the cad and taped the other side and removed the tape from the front and replaced it with suede. when it was dry I removed the tape.

 

http://farm9.staticflickr.com/8246/8664268339_d3bd3af85e_z.jpg

IMG_3408 by my0771, on Flickr

 

Earlier I mentioned I had cut a top and bottom piece of card these became the inserts for the lid and base again covered in cobalt blue suede.

 

I sealed the outside of the box with shellac sanding sealer before fixing any of the suede in place.

 

http://farm9.staticflickr.com/8114/8660143399_07da81c7bb_z.jpg

IMG_3415 by my0771, on Flickr

 

I have waxed the sealed box and have started fitting the suede into place.

Unfortunatley I did not allow enough clearence for the suede as I did not know how thick it would be I have therefore sanded each edge of each tray to make them fit I am now adjusting the height of each tray so the lid will close correctly.

 

You are now fully up to date with my first bigger box project.

Thanks for looking

Michael

Edited April 20, 2013 by my63

[mhguda]

I can feel in my bones that this is going to be a beautiful box!

[The Good Captain]

I was asked by fpn member alc3261 to make a box to fit a space on her desk.

Let's hope that the size of the space never changes or alters. What would she do then?

[alc3261]

I will move other things about!!

[Pentulant]

beautiful!

[The Good Captain]

I will move other things about!!

I'd never have though of that...

[my63]

Trays are my thing at the moment normally I would use felt for the bottom of the trays not today this is American red oak.

 

http://farm9.staticflickr.com/8126/8669948026_158d837984_z.jpg

IMG_3424_1 by my0771, on Flickr

 

The inside is fitted now although it has a little sawdust around it at the moment

 

http://farm9.staticflickr.com/8522/8669950618_b4e95c27a2_z.jpg

IMG_3428_1 by my0771, on Flickr

 

http://farm9.staticflickr.com/8533/8669952366_199cf6daa4_z.jpg

IMG_3430_1 by my0771, on Flickr.

 

The third tray needs a little more attention as it has been made with the plywood on the bottom.

This tray is desgined to remain in the box however it still needs to be right just in case it is ever removed. In the same way that no one is likely to look at the bottom of the trays they still need to be right.

Thanks for looking

Michael

[my63]

I have made some progress on the trays today as well as making a couple of little boxes

 

 

corner of the top tray

http://farm9.staticflickr.com/8545/8676071928_96b2e6ce8e_z.jpg

IMG_3474_1 by my0771, on Flickr

 

Veneered bottom of the top tray

http://farm9.staticflickr.com/8263/8674965007_19421dfc36_z.jpg

IMG_3473_1 by my0771, on Flickr

 

I noticed today that there is a crease in the suede on the inside of the lid I will make a new piece tomorrow.

 

Thanks

 

Michael

[my63]

I would like to share the final stages of this project

 

This is the inside of the box

 

http://farm9.staticflickr.com/8122/8685504773_3ef1cde611_z.jpg
IMG_3495 by my0771, on Flickr

 

Lower tray for large pens

http://farm9.staticflickr.com/8543/8686624322_c64304419d_z.jpg
IMG_3496 by my0771, on Flickr

 

Second tray for smaller pens

http://farm9.staticflickr.com/8393/8685507325_f13fcf2554_z.jpg
IMG_3500 by my0771, on Flickr

 

Third tray for smaller pens

http://farm9.staticflickr.com/8540/8685507983_ee6b97123f_z.jpg
IMG_3501 by my0771, on Flickr

 

Bottom of tray with protective pads

http://farm9.staticflickr.com/8539/8685512407_33d2fdc2cb_z.jpg
IMG_3505_1 by my0771, on Flickr

 

 

Thanks for looking

Michael

Edited April 28, 2013 by my63

[my63]

Here is alc3261s finished box complete with trays

 

http://farm9.staticflickr.com/8532/8683413706_a29be923fd_z.jpg
IMG_0421 by my0771, on Flickr

 

http://farm9.staticflickr.com/8535/8682299755_77aca8bd28_z.jpg
IMG_0418 by my0771, on Flickr

 

http://farm9.staticflickr.com/8527/8682297885_9e996d9d1e_z.jpg
IMG_0412 by my0771, on Flickr

 

Thanks for looking

Michael

[View from the Loft]

Wow, both of these boxes are beautiful. Time for me to work out what size and save my pennies while I take my place in the queue.

[my63]

Wow, both of these boxes are beautiful. Time for me to work out what size and save my pennies while I take my place in the queue.

Different lighting different cameras but the same box sorry for any confusion it will be off to its new owner soon

 

M

[alc3261]

The finished box is lovely, I can't wait to see it "in the flesh"!!

[OakIris]

That turned out beautifully, Michael! I thought the blue suede might be a bit too bright, but it looks very nice indeed with the dark wood of the walnut. You must be very pleased, alc3261.

 

Holly

[my63]

It has been apleasure to make it for you and I hope that you enjoy it for many years.

Michael

[PensMakeMemories]

Just outstanding! If you don't mind my asking; about what are the dimensions of that box?

[my63]

Hi PensMakeMemories

This box was custom made to Alc3261 s diemensions to fit a space on her desk if I remember correctly it holds 36 standard pens and 9 oversize pens.

The dimensions are 390mm x 260mm x 100mm it was made from solid oak with brazilian walnut veneer and walnut edging.

The interior is oak trays with cobalt blue suede.

It has been delivered to its owner and I hope that she is happy with it.

 

Michael

[PensMakeMemories]

Thank you very much! That seems to be a very reasonable size for a pen box that holds 45 pens, I was worried something like that would be much larger.

[my63]

This was the first large box that I have made from scratch I did seek some advice from a woodworking forum regarding the mitre joints which I strengthened following that advice.

I really enjoyed the project Alc3261 selected the suede colour and then let me do the rest which was great.

if I can help you in any way just ask

Regards

Michael

[my63]

Next project

I have a writing slope that i am working on however I bought this veneer some time ago and I am thinking of making a box to show it off the wood is chillean laurel burr/burl depending on where you are in the world.

 

http://farm9.staticflickr.com/8232/8447614457_6250dcbd2b.jpg
chillean laurel by my0771, on Flickr

 

I can see the box in my mind with the veneer in the picture turned on its side folded over the sides of the box then french polished to a high gloss.

 

I think its a shame to veneer over lovely oak so i am going to experiment with plywood for this box.

 

If anyone has any thoughts I would love to hear them

 

Thanks for looking

 

Michael