Figure 8 Tapered Twin Starboxes

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Blog entry by BertFlores58 posted 11-30-2012 12:29 PM 1593 reads 1 time favorited 13 comments Add to Favorites Watch

This project started from starbox that was with wooden hinge. It was addictive to challenge myself in making hinges from different type of wood. This project came up only without any plans because I could not make it in sketchup. Martyn (Britboxmaker) was really helpful. On one of the comments, he drawn the box using the TURBOCAD.. Much to learn from my side…

So here it goes….

1. Making the cover was done first…. to estimate how much I need for the stars to extend. Whatever available parquet (2×4 floor tiles Narra) I could cut. Then try to mix other color to give contrast. Not a good contrast though the design of a star makes it outstanding.

2. Tapered pentabox…. Using the compound miter saw…. Set it to 5 degree horizotal offset from 90 deg and 72 degree vertical to make pentagon. This was done on the 3 corners… The plan for the center dividing stock is done mathematically by taking the offset of 72 on the vertical.. Glue one piece first then joined the other half completing the figure 8..

3. Leveling the bottom and top. I did not expect that cutting 5 degree with 90 degree will result to this..

The top and bottom needs to be sanded…. so I did. Pencilled in against a flat granite then start by handplane… later with sanding manually using the flat surface and sandpaper. Here is the final…

4. Working on the hinge. The wooden hinge is made from a very strong wood but not brittle and dense. I dont have any idea what kind of wood is this. From recycled of course… I made the groove using a portable router with straight bit 1/8 then cut the slots on the cover first… I avoided the star points not to be destroyed. Next, the permanent one.. The other piece was patterned to the first. I haven’t taken photos in doing this but if you are interested I will make a video next time… This is the final thing how it looks like.

5. Assembly for bottom and the hinge. The use of dowel made it possible in making a quick clamp for this work. Without dowel, there is no way to clamp these… yes it is possible to put weights on the top but not really promising that it will not be moving. Here is how it looks:

The dowel used is a chopstick made from bamboo.. cheap but in the right size 5 mm dia. The hardest part is you have to drill it manually… it is not perpendicular… At least I missed two.. One on the top hinge…. the other on the bottom just slightly protruding on the outside wall…. No bad.

The bottom with dowel… The easiest flooring to do but this is very strong because the pins are inserted in inclined position locking the board in place.

HERE IS THE FINAL MAKE…. Ready for trimming and finishing tomorrow. Till next time…
Have a nice day.

-- Bert

13 comments so far

View SPalm's profile


5321 posts in 3934 days

#1 posted 11-30-2012 01:22 PM

Wow Bert. What a challenge.
Love the bamboo chopsticks. Good stuff.


-- -- I'm no rocket surgeon

View BertFlores58's profile


1698 posts in 2974 days

#2 posted 11-30-2012 01:31 PM

Thanks Steve. Actually, bamboo is very resillient. It follows the dowel hole with ease. It comes also on different sizes . I use barbeque stick for a 4 mm dowel and in some cases I just pass it through to a desired drilled hole in metal plate to make the required pin. I use it also for plugging nail holes as it squeze trought it.
Have a nice day.

-- Bert

View BritBoxmaker's profile


4611 posts in 3089 days

#3 posted 11-30-2012 01:32 PM

Very neat, Bert. Good idea with the Bamboo pins. An underrated material. Very Flexible in its uses. Considering you had no drawings to refer to a very good build.

-- Martyn -- Boxologist, Pattern Juggler and Candyman of the visually challenging.

View BertFlores58's profile


1698 posts in 2974 days

#4 posted 11-30-2012 01:41 PM

Thanks Martyn,
I am looking at the next one… remember the rainbow box… It is still here at my side.. waiting for assembly.
Hope I can finish them one by one… My problem is that when I think of something else, I start immediately and forgot the others. I love challenges….

-- Bert

View Sheila Landry (scrollgirl)'s profile

Sheila Landry (scrollgirl)

9231 posts in 2972 days

#5 posted 11-30-2012 01:43 PM

Wow again, Bert! Not only a complex design, but tapered too Quite an undertaking! But boy – it is looking good! You are quite the inspiration, my friend! Very, very cool!


-- Designer/Artist/Teacher. Owner of Sheila Landry Designs ( Scroll saw, wood working and painting patterns and surfaces. "Knowledge is Power"

View BertFlores58's profile


1698 posts in 2974 days

#6 posted 11-30-2012 02:42 PM

Thanks Sheila. There are times that we really have to try all the possibilities as we always win and there is nothing to lose but indeed in this undertaking a lot of thinking while doing it is exhausting. It is really worth sharing to inspire as it is also comes from everyone in LJ who had inspired me in return.
God bless.

-- Bert

View BTimmons's profile


2303 posts in 2537 days

#7 posted 11-30-2012 03:50 PM

Yikes. I’m not enough of a masochist to involve myself with the kind of math that’s required for a project like this! You have my admiration.

-- Brian Timmons -

View shipwright's profile


8006 posts in 2850 days

#8 posted 11-30-2012 04:16 PM

Great idea and, as always, great execution Bert.
You have some creative imagination, my friend.

-- Paul M ..............If God wanted us to have fiberglass boats he would have given us fibreglass trees.

View DocSavage45's profile


8639 posts in 2895 days

#9 posted 11-30-2012 06:02 PM

I am in awe of your creativity and woodworking skills! Thanks for sharing and stimulating my mind! LOL! :-)

-- Cau Haus Designs, Thomas J. Tieffenbacher

View a1Jim's profile


117160 posts in 3629 days

#10 posted 11-30-2012 06:25 PM

This is fantastic Bert great job.

-- wood crafting & woodworking classes

View Jamie Speirs's profile

Jamie Speirs

4168 posts in 2909 days

#11 posted 11-30-2012 06:32 PM

Bert, ingenious

A great project,


-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View littlecope's profile


3071 posts in 3554 days

#12 posted 12-01-2012 12:31 AM

Excellent Work Bert!!
I’m looking forward to seeing it with the Finish applied!!

-- Mike in Concord, NH---Unpleasant tasks are simply worthy challenges to improve skills.

View BertFlores58's profile


1698 posts in 2974 days

#13 posted 12-01-2012 03:36 AM

Thanks to all,
Have a nice weekend.

-- Bert

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