The Design. The two-color concept gives me an idea of using two colors of wood that are contrasting. With the limitation of making contrast, a big board requires stripes motif or grilled motif to give the necessary symmetry of a solid wall. A diamond grill makes it so attractive with a background wall in it.
The Wood. Since dull red Narra (from old floor parquet flooring) and a few strips of white board (probably a hard pine from crate) are available, the red and white grill can be done.
The board ready for assembly. The sides are made from 1 long board. Cut to desired point the intersection meets. The top portion is formed without plan. I made a mosaic out by making the square corners meet each other. The center design is just what comes out from my mind based on the available wood. Notice that the double strips (the Y is made up of two white strips sandwiching the brown veneer.
Mitering. Martyn given me this method but I do it my way using the portable router and a guide pinned in the board. I am not using a clamp as it is difficult to handle making the board to be fixed in a table.
The masking tape is just to protect the board from glue smear.. Notice the cover is also mitered with 45 deg chamfer.
The Assembly. Bend all the sides and just taped them. No use of clamps here. As long as the grooves are perfectly perpendicular, it will create perfect miter joints on the top and sides.
Cutting the lid from base. The only one that holds the sides is the top lid and cutting the side can be dangerous of losing the form. I took the risk anyway and just leave the tape in place until glue is dry.
The LIPPINGS. I selected a Philippine hardwood that is strong and stable. This is “Madre de Cacao” (Old tree and very hard to cut) found in an orchid stand. My target is to have a 45 degree quarter cut. In order to have good accuracy, 2 portable router been used. Each has its own guide. Set for cutting the bevel first and followed by the other who will cut the second. TS will be better to cut this wood. I broke the 1/8 straight bit I used. Good to have a spare.. (Thanks to Randy who had given me 3 pcs on this. I still have the last one. It’s time for me to order bits.) Here are series of photos how the lippings are installed.
The Madre de Cacao…..
After cutting by router and chamfering…
Tape out, glue out, and lipping is on. This has to be completely dry for machining the lipping to its target height and surface.
Notice the protrusion of the lipping. This has to be routed both the excess and the face.
Fitting the bottom board. I have selected a dark brown Tanguile… a timber same quality as Philippine mahogany. A dado helps more strength for gluing.
Finally, all the work on the box is done. Sanding and finishing is the next issue.
You will never see a box like this… perfect in line as if the grill is fixed in the wood itself… (It looks like an inlay.)
The next issue will be interesting… I plan to use a wooden hinges and a front lid key and hasp.
Thanks for everyone,