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Blog series by Andy updated 02-03-2012 04:43 PM 8 parts 37651 reads 139 comments total

Part 1: How it started

12-28-2011 01:03 AM by Andy | 11 comments »

This blog will show progress on an ArtBox I am building for a client. In September I received an email from a gentleman named Sean asking if I was interested in making a custom box to display his wrist watch collection. I said I typically dont do commission work for several reasons, but if he wanted to send me details I would look it over before deciding.We worked out the bugs and I agreed to make a box to hold eight watches. The color of the wood and the grain were important as well as...

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Part 2: Cutting and assembly

12-28-2011 01:24 AM by Andy | 8 comments »

I carefully laid out the compartments on a sheet of plywood to be sure it would give the customer the room required. I then marked my cuts out for the body on the only piece of bloodwood I had left. I cut the board to the width of all four sides and slotted a kerf for the bottom. Here is a test piece of 1/4” ply. I mitered the sides and then cut slots for splines to add strength and dress it up a little. I used maple and wenge for the splines. This is how the spline...

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Part 3: Fitting the medallion

12-28-2011 01:47 AM by Andy | 7 comments »

I cut the lid a little oversize and made a jig to route out for the maple center panel (medallion). And after. I always make a test piece to size the real insert to. And here is the maple insert prior to rounding the corners which I do by eye on a disc sander and final fit with a sanding block a little at a time. Stay tuned

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Part 4: Glueing in the medallion

12-28-2011 02:42 AM by Andy | 13 comments »

This shows the medallion getting glued in place. I decided to do a loose fit between the medallion and lid on this one due to the fact that I just couldn keep the bloodwood from chipping out even with a new cutter and climb cutting. I have done this before, filling the gap with black epoxy for a shadow line effect. I am using spacers to even out the gap. Before fitting the medallion I had ran a router around the inside of the box and cut a 3/8” x 3/8” rabbit for the lid to ...

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Part 5: Hinges, Handle, Dividers

12-30-2011 05:17 PM by Andy | 11 comments »

After glueing in the medallion, I went ahead and sanded it flush with the lid. I did this to be sure it looked ok. I was worried about chipped out areas below the rim showing up after the sanding and it would be much easier to replace the panel at this stage before the entire box was shaped. It would make aligning the jig for recutting the recess less of a nightmare. But it looked fine. The handle is a piece of cut off from the Maple medallion. I simply slotted a mortise in it and the lid ...

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Part 6: Handle replaced, shaping started

01-11-2012 12:07 AM by Andy | 27 comments »

The handle.I did not like how the handle was looking, it appeared to lack any of the swirling grain that the top inset panel has. That happens sometimes after shaping, the good stuff ends up on the floor. Also… if you look close, you will notice in the picture below that I sanded too deep into the right corner of the handle and exposed the spline! Oops! So I made a new one from Black Palm Wood, a first time for me. The black color ties in with the Wenge corner splines, plus I love ...

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Part 7: OOPS!!

02-02-2012 05:26 PM by Andy | 22 comments »

This is why its been awhile since my last post. One of the problems with shaping wood to this extent is any flaws show up. Figured Bigleaf Maple, aka Western Maple, Oregon Maple, Acer macrophyllum, can have pits, bark inclusions, etc… Well, I found a few during the final shaping. I knew I was getting pretty close to maximum depth in one corner, but I couldnt leave that little black spot glaring at me. Then I was all the way through and exposing the bloodwood below, nothing ...

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Part 8: Finished

02-03-2012 04:43 PM by Andy | 40 comments »

Finally I got it done and shipped it off to the customer. He wont get it in his hands until next week, so I will post his impressions when I hear back. I hope its what he wants!!! TIP:Some of you may know about this but many will not. This is my secret to quickly fine sand the box prior to spraying lacquer. I hand sanded down to 220 and then I finish up with green nylon pads. These were bought at the local dollar store. Guess how much? Thats right, a whole dollar. You can buy similar pads ...

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