TWO-COLOR CONCEPT #2: Hexagonal Box - Part 2

For the second time that I have to continue the making of hexabox under the two tone concept.

The first part ended in the mitering using a 45 degree chamfering bit by router manually.

STEP 4. The Assembly

After routing and ready for assemble..

Notice the gap caused by using the 45 degree instead of the 60 degree.. I need to caulk it with 30 degree wedges.

The priority is the sides have to be erected perpendicular and insert the caulking pieces so I have to make glue the bottom and the sides first. Above is the situation where the boards are now protected from glue smear with masking tape.

Look after gluing…

STEP 5 – Making the caulking pieces. Using the sliding compound miter saw.. I made the caulking pieces. I use the same wood… NARRA not so hardwood because it will not absorb much glue. I need the glue to hold on tight and join the sides.

the caulking pieces… wedges made by miter saw and cut accross the grain. This will make a good surface on the inside joint of the sides.

Here is the totally assembled pieces box completed with the caulking piece.

Notice how the wedges exactly filled the gaps.

After removal of the tapes….

The clean surface after removal… no smear of glue.

Notice the glue smear on the tapes.

STEP 6. The Lid.
The same technique when making the bottom…. however careful on the ends as it easily splits.
Herebelow the lid and the box.

The most important in making the lid to fit exactly is to use a template..

This is the one I use… a plywood of 1/8 inch thick. At least it is stable.. I use a double sided tape to hold it and also the lid on the table where I will route. A good technique to take out the ds tape is to use a masking tape and stick it to the ds tape. DS tape sticks to the masking tape can easily be peeled off the boards.

STEP 7. The finishing.

I use an artist brush to spread out the lacquer. Dead flat lacquer on several coats becomes glossy like a satin finish. The good thing is… dries quickly.. and several coats can be made in a day.

Here is the final product.

It is already posted….as project.

I am glad that I was able to fulfill this without hesitation on the problems being faced. I even made twice the post because I want everyone to know the techniques here.

Thanks for everyone who had appreciated the project…. Welcome to all.

There will be a next one… bigger… already under construction.. Watch for it.

God bless to all.

-- Bert