LumberJocks Woodworking Forum banner
41K views 71 replies 20 participants last post by  JoeyG 
#1 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
 

Attachments

See less See more
4
#2 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
That's a good catch.

It can look weavy or fiery dependent how you look at it.

Man 2 hour trip to the lumber yard… I have one 5 minutes away from me.
 

Attachments

#3 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
Hi:
That is some great looking lumber. Would you mind telling another Virginian where you found this beautiful material?
Thank You Looking forward to seeing the finished boxes.
 

Attachments

#4 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
one word SCORE!!!!!
that boards looks great
 

Attachments

#5 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
Hi Bigrock, I am no longer in Virginia, I live in North Carolina, but depending on where you are in Virginia it may be worth the trip or you can go to their web site, they do mail order. Of coarse that's never as good as digging through the lumber yourself. I bought these boards from Steve Wall Lumber Co. They are in Mayodan NC. Thats about a hour south of Roanoke Va on Route 220. Here is there web page.

http://www.walllumber.com/about.asp

I have found they have some great prices and a great selection.

@ Ianwater, I have a couple of lumberyards that are closer, but they are way more expensive and rarely have anything really nice. You are lucky that your supplier is so close. I wish mine was. I am fairly new to my area and I am sure there are more places, I just haven't found them yet. For the prices and quality, it is worth the drive.

@ Eddy. I have to agree. I saw them and could not leave them at the yard. Please join them on their way to becoming boxes. So far I am enjoying this blog thing and hope you guys will enjoy it as well.
 

Attachments

#6 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
You've found some fantastic maple. I'm green with envy…
 

Attachments

#7 ·
The Boards

Wood Automotive tire Floor Flooring Hardwood


Wood Floor Flooring Road surface Hardwood


I went to the lumberyard the other day with a detailed list of what I needed to complete my Christmas orders.
Then I go and find this. Needless to say I did not get everything on my list, since every penny was accounted for. I will be making the 2 hour round trip to pick up the remainder of my list soon, but I could not pass this up. Coming in at $20, I got two boards 6" X 72" and surfaced to 13/16. I normally buy in the rough and mill it down myself (I like the surprise) but as I said, I could not pass these up.

I have been asked to do a blog on my epoxy inlays, so I figured I would practice by doing one about the journey of these boards into boxes. My wife and daughter went to swim with the dolphins at Discovery Cove at the beginning of the month and I thought that a matching set would help them both to remember their incredible journey together. You fellow LJ's, get to join me and these boards into hopefully wonderful gifts.
Thanks Hal, I just went and looked and you have come across some gorgeous lumber yourself. I posted the lumberyard above that I got them from. They had a few more boards of it a week ago. If you don't mind paying shipping then give them a look. Every time I go in there I drool over something they have. Most are still out of my price range, but every commission brings me a little closer to that special piece. Then I will make something for myself.
 

Attachments

#8 ·
Pieces milled and cut

Table Wood Tool Gas Wood stain


So here is the next phase in the early life of a box.

After straight lining one of the boards and cutting to a rough length for my project, I split the board in half. I usually go for 3/8 or a little larger but since these boards were already surfaced I couldn't make them thicker. LOL. I ended up a little proud of 5/16 thick. I know a lot of people make there boxes 3/4 thick but this way works better for me. I will add to the interior once the lid is sized and everything is together. Trust me. It sounds wacked but as I said, it works for me.

After splitting the board and planing, I pull out the old miter sled and set the table saw to 45 degrees and cut the pieces to size. Set stop is designing and cutting the bottom detail. I'll post once I get it done.

Thanks for following along on this journey.
 

Attachments

#9 ·
Pieces milled and cut

Table Wood Tool Gas Wood stain


So here is the next phase in the early life of a box.

After straight lining one of the boards and cutting to a rough length for my project, I split the board in half. I usually go for 3/8 or a little larger but since these boards were already surfaced I couldn't make them thicker. LOL. I ended up a little proud of 5/16 thick. I know a lot of people make there boxes 3/4 thick but this way works better for me. I will add to the interior once the lid is sized and everything is together. Trust me. It sounds wacked but as I said, it works for me.

After splitting the board and planing, I pull out the old miter sled and set the table saw to 45 degrees and cut the pieces to size. Set stop is designing and cutting the bottom detail. I'll post once I get it done.

Thanks for following along on this journey.
It's not a very good picture, but I am sure you get the idea.
 

Attachments

#10 ·
Bottom Detail

Rectangle Wood Font Wood stain Hardwood


Wood Rectangle Bumper Font Automotive exterior


Wood Rectangle Font Bumper Automotive exterior


Here I have laid out a design for the bottom detail that I liked, cut it out with my jig saw, and finished up with a 1" drum sander on my drill press. I have a few more boxes to do this to but hopefully I will have a box to show how tomorrow. I am also going to try to remember to take pictures of each step.

Thanks for taking a look.
 

Attachments

#11 ·
Now I have a box

So first I sanded up the bottom detail using a drum sander on my ancient drill press
Wood Wood stain Flooring Art Hardwood


Table Wood Plant Rectangle Wood stain


next I cut the dado for the bottom to set in. I don't have a dado blade so I just make multiple passes on the table saw.
Wood Table Rectangle Flooring Floor


After that is done, I move on to sand the inside of the box. Since it is nearly impossible to do after the box is together this is the perfect time to do it.
Wood Walking shoe Grey Flooring Floor


Now it's just a little glue and some tape. I have found that with boxes this small tape is more than enough. Trying to use clamps is a exercise in frustration and I don't think they are needed. As long as you miters are true the box wants to go together on it's on. I use the tape across the top of the corners to pull it into square if it needs it. and just to hold it there if it doesn't.
Wood Flooring Hardwood Wood stain Art


Wood Gesture Finger Flooring Hardwood


And since it takes just about to the same amount of time to do 9 boxes as it does to do 1, I did 9
Wood Automotive tire Gas Flooring Machine


Next stop will be lids

Thanks for joining me on this journey, This is a learning experience for me and as with all things, I hope to get better at this blog thing as I go. Until next time happy sawdust making.
 

Attachments

#12 ·
Now I have a box

So first I sanded up the bottom detail using a drum sander on my ancient drill press
Wood Wood stain Flooring Art Hardwood


Table Wood Plant Rectangle Wood stain


next I cut the dado for the bottom to set in. I don't have a dado blade so I just make multiple passes on the table saw.
Wood Table Rectangle Flooring Floor


After that is done, I move on to sand the inside of the box. Since it is nearly impossible to do after the box is together this is the perfect time to do it.
Wood Walking shoe Grey Flooring Floor


Now it's just a little glue and some tape. I have found that with boxes this small tape is more than enough. Trying to use clamps is a exercise in frustration and I don't think they are needed. As long as you miters are true the box wants to go together on it's on. I use the tape across the top of the corners to pull it into square if it needs it. and just to hold it there if it doesn't.
Wood Flooring Hardwood Wood stain Art


Wood Gesture Finger Flooring Hardwood


And since it takes just about to the same amount of time to do 9 boxes as it does to do 1, I did 9
Wood Automotive tire Gas Flooring Machine


Next stop will be lids

Thanks for joining me on this journey, This is a learning experience for me and as with all things, I hope to get better at this blog thing as I go. Until next time happy sawdust making.
Looks like you are making great progress! The boxes are looking good.
 

Attachments

#17 ·
Lids and Miter Keys

Table Wood Wood stain Flooring Hardwood

I use my table saw sled to square up the lid and cut it to size

Wood Gas Machine Hardwood Room

Then it's on to the jointer where I size the width of the lids. I like to make mine about 1/16 smaller at this point. Final sanding should bring it down the rest of the way. I try to end up with about 1/16 gap all the way around.
Wood Hardwood Rectangle Wood stain Flooring

I have ripped scrap pine that just sit in the box and holds the lid in place. This will be need when I go to drill for lid pins. It also lets me see where the lid will sit. This time I felt like letting them sit a little proud of the box. I will blend them together when I shape and sand the box.

Wood Floor Flooring Art Hardwood


Then I move on to marking out for the miter keys

Wood Floor Hardwood Flooring Wood stain


Here you see the box holder I built for my sled that holds my box while I cut the keys in.

Wood Art Artifact Engineering Sculpture


Who has the key to this tower? I guess I will have to make them.

Table Wood Art Building Flooring


This is another box I am working on also, You can see the keys in place here.

Next step is to put in lid pins and keys. Stay tuned.
 

Attachments

#18 ·
Lids and Miter Keys

Table Wood Wood stain Flooring Hardwood

I use my table saw sled to square up the lid and cut it to size

Wood Gas Machine Hardwood Room

Then it's on to the jointer where I size the width of the lids. I like to make mine about 1/16 smaller at this point. Final sanding should bring it down the rest of the way. I try to end up with about 1/16 gap all the way around.
Wood Hardwood Rectangle Wood stain Flooring

I have ripped scrap pine that just sit in the box and holds the lid in place. This will be need when I go to drill for lid pins. It also lets me see where the lid will sit. This time I felt like letting them sit a little proud of the box. I will blend them together when I shape and sand the box.

Wood Floor Flooring Art Hardwood


Then I move on to marking out for the miter keys

Wood Floor Hardwood Flooring Wood stain


Here you see the box holder I built for my sled that holds my box while I cut the keys in.

Wood Art Artifact Engineering Sculpture


Who has the key to this tower? I guess I will have to make them.

Table Wood Art Building Flooring


This is another box I am working on also, You can see the keys in place here.

Next step is to put in lid pins and keys. Stay tuned.
A quick tip, When milling curly or birdseye maple, We all know how it tends to blow out on you. I wax up my jointer and planer and then moisten the maple with a damp sponge. I don't want to make the board wet, just soften the wood fibers. Doing it this way has saved me a lot of cussing. I haven't had any issues with my equipment rusting since I am always sure to wax it up well, and wipe it off after words. I use Johnson's paste wax on all my tools to prevent rust and so the material feeds in smoothly. I have never had a problem with the wax on the wood, since it is sanded several times after the initial milling steps.
 

Attachments

#22 ·
carving the inlay

As I mentioned at the beginning of this, these two boxes will be for my wife and daughter. Today I was able to get back to working on them and did a little carving on the lids. If you would like to see more about how I do my epoxy inlays you can check it out at http://lumberjocks.com/JoeyG/blog/26663. I am not going into a lot of detail, since most of it is covered there. I just wanted to share the pictures of the progress and keep this as up to date as possible.

You will notice that I have the Discovery Cove logo, flipped on the lids. I did this for two reasons. First is that my wife is left handed and my daughter is right handed. So there will be a left and right box. While some may argue that I should have left the logo alone and still made a left and right handed box, I like the idea of having them as mirror images of each other.

Wood Rectangle Flooring Art Table


Green Textile Rectangle Wood Flooring


Wood Rectangle Creative arts Art Flooring


Table Textile Wood Adhesive Rectangle


Fin Grey Fish Wood Art


Sleeve Wood Grey Fin Art


Wood Table Beige Hardwood Flooring


Wood Flooring Floor Hardwood Art


Until next time be safe in the shop.

Wood Rectangle Beige Pattern Art
 

Attachments

#23 ·
carving the inlay

As I mentioned at the beginning of this, these two boxes will be for my wife and daughter. Today I was able to get back to working on them and did a little carving on the lids. If you would like to see more about how I do my epoxy inlays you can check it out at http://lumberjocks.com/JoeyG/blog/26663. I am not going into a lot of detail, since most of it is covered there. I just wanted to share the pictures of the progress and keep this as up to date as possible.

You will notice that I have the Discovery Cove logo, flipped on the lids. I did this for two reasons. First is that my wife is left handed and my daughter is right handed. So there will be a left and right box. While some may argue that I should have left the logo alone and still made a left and right handed box, I like the idea of having them as mirror images of each other.

Wood Rectangle Flooring Art Table


Green Textile Rectangle Wood Flooring


Wood Rectangle Creative arts Art Flooring


Table Textile Wood Adhesive Rectangle


Fin Grey Fish Wood Art


Sleeve Wood Grey Fin Art


Wood Table Beige Hardwood Flooring


Wood Flooring Floor Hardwood Art


Until next time be safe in the shop.

Wood Rectangle Beige Pattern Art
great work joey
the waves in these is gorgeous
and goes with the dolphin inlays

i like the reasoning in your approach
the girls will both love them

i do the same when i make mating
boxes for a couple or the children

as they are reflections of each other
i do that in the boxes too
Brown Rectangle Wood Amber Luggage and bags
 

Attachments

#29 ·
The inlay

Here is a coffee cup my daughter picked out for me while at Discovery Cove, Orlando, FL. I thought you would like to see my inspiration for this part of the project.

Tableware Drinkware Dishware Coffee cup Cup


Rectangle Wood Grey Art Flooring


Wood Pattern Electric blue Rectangle Hardwood


Hood Blue Wood Rectangle Art


Above is the carving filled with epoxy and sanded. Now to clean out air bubble craters and epoxy again. I love this blue, it has a metallic flake in it that looks great.

Until next time,

Joey
 

Attachments

#30 ·
The inlay

Here is a coffee cup my daughter picked out for me while at Discovery Cove, Orlando, FL. I thought you would like to see my inspiration for this part of the project.

Tableware Drinkware Dishware Coffee cup Cup


Rectangle Wood Grey Art Flooring


Wood Pattern Electric blue Rectangle Hardwood


Hood Blue Wood Rectangle Art


Above is the carving filled with epoxy and sanded. Now to clean out air bubble craters and epoxy again. I love this blue, it has a metallic flake in it that looks great.

Until next time,

Joey
Great use of the wood grain to combine with the subject matter! Cant wait to see this one finished!
 

Attachments

#34 ·
Attching the lid

First I tape blocks in that I have sized for the position I want the lid to sit
Green Wood Automotive tire Rectangle Tire


I then tape the lid in place.
Green World Wood Art Rectangle


Next is to mark out and drill for the hinge pins
Wood Flooring Adhesive Wood stain Hardwood


Brush Finger Hand tool Paint Engineering


Gas Wood Automotive tire Bumper Machine


Wood Rectangle Flooring Hardwood Font


I think the pictures show my process fairly well. If you have any questions or suggestions please leave them and hopefully we will all learn a little from each other.

Next stop is get the lids opening correctly and then handles.

Thanks for taking a look.
 

Attachments

#35 ·
Attching the lid

First I tape blocks in that I have sized for the position I want the lid to sit
Green Wood Automotive tire Rectangle Tire


I then tape the lid in place.
Green World Wood Art Rectangle


Next is to mark out and drill for the hinge pins
Wood Flooring Adhesive Wood stain Hardwood


Brush Finger Hand tool Paint Engineering


Gas Wood Automotive tire Bumper Machine


Wood Rectangle Flooring Hardwood Font


I think the pictures show my process fairly well. If you have any questions or suggestions please leave them and hopefully we will all learn a little from each other.

Next stop is get the lids opening correctly and then handles.

Thanks for taking a look.
well done joey

it is good to watch
as you learn
and show us all
the processes

tank you

nice work
 

Attachments

#41 ·
handle, lid, and finishing the inside

Wood Computer keyboard Gas Engineering Tool


Rectangle Table Wood Tableware Office equipment


Above you see the handles attached. After deciding the general shape of the handle and the location I drilled holes and inserted dowels, then glued them up

Next I slide the nails back into place and mark where the handle falls on the side of the box.
Blue Wood Finger Rectangle Wood stain


Tableware Drinkware Table Dishware Cup


Once the area that needs to be removed for the handle is marked I use a flush cutting saw (my best cutting saw) a coping saw, and a sharp chisel to remove the material
Automotive tire Wood Finger Bumper Automotive exterior


Automotive tire Wood Finger Tire Tread


Tableware Kitchen utensil Table Wood Cutlery


Then I reinsert the nails and check for a good fit. This is why I use nails, the lid has to be put on and taken off over and over to make a good fit.
Table Wood Automotive design Flooring Art


At this point I like to finish the insides. I finish both the inside of the box and the edges and bottom of the lid. It makes everything a lot easier, and I have found it is almost impossible to get a good finish on if it is done any later than this.
Tin Tin can Gas Cylinder Aluminum can


Then I sand the nails with 80 grit paper, insert them until the point just holds the lid in place. I then apply the CA glue to about 1/2 of the nail that is still exposed and gently tap in place. I make sure the lid is aligned, add a little extra glue to the hole just for good measure and set a side.
Wood Creative arts Rectangle Tool Art


Wood Sleeve Safety glove Collar Gas


I want to point out here that is is very important to get the whole drilled the correct size for what ever you are using for the hinge pin. The pin attaches in the sides and the lid rotates around it. I do it this way because it is visible on the out side of the box. I also caution you to be careful as you remove and attach the lid. Pull the nail straight out. Try not to rock it back and forth to get it out because this makes the hole bigger and can create problems when you try to glue the pin in place.

Well Christmas is getting close and so is the end of this blog. There are only a few more steps and I'll be back soon to share them with you. Thanks for coming along this journey, see you next time.

Joey
 

Attachments

#42 ·
handle, lid, and finishing the inside

Wood Computer keyboard Gas Engineering Tool


Rectangle Table Wood Tableware Office equipment


Above you see the handles attached. After deciding the general shape of the handle and the location I drilled holes and inserted dowels, then glued them up

Next I slide the nails back into place and mark where the handle falls on the side of the box.
Blue Wood Finger Rectangle Wood stain


Tableware Drinkware Table Dishware Cup


Once the area that needs to be removed for the handle is marked I use a flush cutting saw (my best cutting saw) a coping saw, and a sharp chisel to remove the material
Automotive tire Wood Finger Bumper Automotive exterior


Automotive tire Wood Finger Tire Tread


Tableware Kitchen utensil Table Wood Cutlery


Then I reinsert the nails and check for a good fit. This is why I use nails, the lid has to be put on and taken off over and over to make a good fit.
Table Wood Automotive design Flooring Art


At this point I like to finish the insides. I finish both the inside of the box and the edges and bottom of the lid. It makes everything a lot easier, and I have found it is almost impossible to get a good finish on if it is done any later than this.
Tin Tin can Gas Cylinder Aluminum can


Then I sand the nails with 80 grit paper, insert them until the point just holds the lid in place. I then apply the CA glue to about 1/2 of the nail that is still exposed and gently tap in place. I make sure the lid is aligned, add a little extra glue to the hole just for good measure and set a side.
Wood Creative arts Rectangle Tool Art


Wood Sleeve Safety glove Collar Gas


I want to point out here that is is very important to get the whole drilled the correct size for what ever you are using for the hinge pin. The pin attaches in the sides and the lid rotates around it. I do it this way because it is visible on the out side of the box. I also caution you to be careful as you remove and attach the lid. Pull the nail straight out. Try not to rock it back and forth to get it out because this makes the hole bigger and can create problems when you try to glue the pin in place.

Well Christmas is getting close and so is the end of this blog. There are only a few more steps and I'll be back soon to share them with you. Thanks for coming along this journey, see you next time.

Joey
Very well documented… looking forward to seeing it finished…
 

Attachments

#45 ·
last steps before the spray booth

My next step is to put a piece of raw cedar inside the box. It servers two purposes. First it is the stop to keep the lid from opening to far and hitting the back of the box possible messing up the finish. Second is to fill the box with that wonderful cedar smell.
Wood Wood stain Hardwood Rectangle Plywood


Liquid Wood Fluid Plastic bottle Wood stain


Now it's time to cut those nails off. I don't get closer that a 1/16 or so to the box. 80 grit paper on the sander takes it down quick enough.
Wood Gas Pliers Hand tool Tool

Wood Bumper Automotive exterior Wood stain Hardwood


Next comes the right angle grinder with a flap sanding disc. I don't remember if this on is 60 or 80 grit. I will not be doing much sculpting on these to boxes, but make sure you have a respirator and plenty of ventilation in the shop. It throws up a lot of dust. I am looking to get goggles for this because I get so much dust in my eyes. I also pull out the fans, open all doors and windows, and keep a change of clothes so I don't carry all that dust into the house. I know that sounds like a lot, but after you have made a sculpted box with a rt angle grinder once, you will see. I like to do it outside when ever possible. As I said this is just a little cosmetic surgery, just to soften it up. I just remember this::: You want to make sure the box is SECURED to your work area. The first time I tried this, I didn't think about it and threw my box across the shop. Thankfully neither me nor the box was injured.
Wood Hardwood Wood stain Gas Tool


Wood Table Rectangle Gas Goggles

I have two more blocks that I screw down to lock the box in place. It makes it a pain and takes time to more the box to where I want it but after that first experience the time is well worth my fingers and all the work I have in the boxes up to this point.
Wood Flooring Rectangle Floor Wood stain


And here they are ready for the spray booth. I didn't take picture of the sanding, I am sure we all know the procedure. I use a bosch orbital sander. my progressing of sandpaper was 80-120-180-220. I will be putting on a coat of polycriylic gloss this afternoon and then check it in the morning. I will look for swirl marks and scratches for the sanding at this point. If I find any I will sand them out, then put on another 3-4 coats of poly sanding with 400 grit paper between each coat. I use a small cup sprayer I will take a pic of for the final entry in this blog. I guess that is about it. I will try to provide pics to go with the finishing, but I am not promising anything more than before and after pics and a picture of the tools used. If you can think of any questions you have about finishing let me know and I will try to document what I would do.
Wood Gas Pattern T-shirt Linens


Thanks,
Joey
 

Attachments

#46 ·
last steps before the spray booth

My next step is to put a piece of raw cedar inside the box. It servers two purposes. First it is the stop to keep the lid from opening to far and hitting the back of the box possible messing up the finish. Second is to fill the box with that wonderful cedar smell.
Wood Wood stain Hardwood Rectangle Plywood


Liquid Wood Fluid Plastic bottle Wood stain


Now it's time to cut those nails off. I don't get closer that a 1/16 or so to the box. 80 grit paper on the sander takes it down quick enough.
Wood Gas Pliers Hand tool Tool

Wood Bumper Automotive exterior Wood stain Hardwood


Next comes the right angle grinder with a flap sanding disc. I don't remember if this on is 60 or 80 grit. I will not be doing much sculpting on these to boxes, but make sure you have a respirator and plenty of ventilation in the shop. It throws up a lot of dust. I am looking to get goggles for this because I get so much dust in my eyes. I also pull out the fans, open all doors and windows, and keep a change of clothes so I don't carry all that dust into the house. I know that sounds like a lot, but after you have made a sculpted box with a rt angle grinder once, you will see. I like to do it outside when ever possible. As I said this is just a little cosmetic surgery, just to soften it up. I just remember this::: You want to make sure the box is SECURED to your work area. The first time I tried this, I didn't think about it and threw my box across the shop. Thankfully neither me nor the box was injured.
Wood Hardwood Wood stain Gas Tool


Wood Table Rectangle Gas Goggles

I have two more blocks that I screw down to lock the box in place. It makes it a pain and takes time to more the box to where I want it but after that first experience the time is well worth my fingers and all the work I have in the boxes up to this point.
Wood Flooring Rectangle Floor Wood stain


And here they are ready for the spray booth. I didn't take picture of the sanding, I am sure we all know the procedure. I use a bosch orbital sander. my progressing of sandpaper was 80-120-180-220. I will be putting on a coat of polycriylic gloss this afternoon and then check it in the morning. I will look for swirl marks and scratches for the sanding at this point. If I find any I will sand them out, then put on another 3-4 coats of poly sanding with 400 grit paper between each coat. I use a small cup sprayer I will take a pic of for the final entry in this blog. I guess that is about it. I will try to provide pics to go with the finishing, but I am not promising anything more than before and after pics and a picture of the tools used. If you can think of any questions you have about finishing let me know and I will try to document what I would do.
Wood Gas Pattern T-shirt Linens


Thanks,
Joey
Hi Joey,

It's coming along nicely.

The handles in the pic seems a little oversized; probably the angle of the pic.
 

Attachments

#54 ·
first coat of poly

This is a quick one.
I sanded everything down to 220 on the orbital, then went over it with 220 by hand. I am still not sure about the handles so I will wait to see what it looks like once the first coat dries. After that it is just a sanding with 400 and recoat until I'm happy with it. Below I show the cup sprayer I use. Nothing fancy but it does a good job. You will also see a couple other boxes that will be gifts as well. I try to always do as many at the same time as possible. It takes the same amount of time to do 10 as it does to do 1.

Final Pictures will be up in a day or two.
Tin Tableware Automotive tire Aluminum can Drinkware


Table Wood Shipping box Flooring Floor


Wood Flooring Table Hardwood Gas


Wood Gas Flooring Hardwood Plywood


Thank you for joining me and these wonderful pieces of wood on the long, but rewarding journey through my shop.

Until next time,
Joey
 

Attachments

#55 ·
first coat of poly

This is a quick one.
I sanded everything down to 220 on the orbital, then went over it with 220 by hand. I am still not sure about the handles so I will wait to see what it looks like once the first coat dries. After that it is just a sanding with 400 and recoat until I'm happy with it. Below I show the cup sprayer I use. Nothing fancy but it does a good job. You will also see a couple other boxes that will be gifts as well. I try to always do as many at the same time as possible. It takes the same amount of time to do 10 as it does to do 1.

Final Pictures will be up in a day or two.
Tin Tableware Automotive tire Aluminum can Drinkware


Table Wood Shipping box Flooring Floor


Wood Flooring Table Hardwood Gas


Wood Gas Flooring Hardwood Plywood


Thank you for joining me and these wonderful pieces of wood on the long, but rewarding journey through my shop.

Until next time,
Joey
Well this is coming along swimmingly…pun intended..
 

Attachments

#59 ·
The finish is nearly done

Sometimes it can be difficult to recall the steps on takes and where I start and stop on this blog. I also tend to switch steps around sometimes depending on how the project is going.

My next step after the first coat of poly on the lids and sides was to flip the box, put 2 coats of poly on, sanding with 400 grit paper in between coats and applying my label. I haven't invested in a branding iron yet so my solution is to use double sided carpet tape and a business card. I will find out how well these stand up to my kids carrying them around the house for a year or so and decide if I need to come up with a new idea. So far these seem very sturdy. The cards I bought have a nice glossy finish on them and we all know how strong carpet tape is.
Wood Rectangle Hardwood Gas Font


Once the bottoms have fully dried I flip them back over, re-sand and add another coat of poly
Wood Flooring Hardwood Wood stain Lumber


Table Wood Flooring Floor Wood stain


I wanted to share this picture with you also. It is a different project but since I am going over finishing a little, I felt that this is kind of important to know and may help you out. As you can see in the picture I have several kinds of wood laminated together and then sanded through. Each wood finishes differently and poses it's own challenges. In this case the poly likes to raise the grain in walnut. This needs to be sanded out and re coated as many times as it takes to get the finish you want. The important thing is that you have to sand everything else a little extra. The padauk will have a high gloss after just a couple of coats, while the walnut will take a few more. To keep it all even I sand down the other woods a little extra. Basically I make sure I take all of the glossiness away from the other woods until I have a uniform dulled look. I will try to capture this in a photo and maybe add it to the comments later. This is one of those times, I am sure someone has a better method or idea and I would love to hear them.
Wood Rectangle Font Pattern Bag


Thanks for joining me, I know I have said that at least every other post, but I truly mean it. I have learned a lot from your comments and from the process of trying to document how I do things. I have to think about what I am doing and why so that I can explain it and I think that doing this blog and helped me become just a little better in the shop.

Thanks again, the next stop will be the finished projects page. Enjoy the dust.

Joey
 

Attachments

#60 ·
The finish is nearly done

Sometimes it can be difficult to recall the steps on takes and where I start and stop on this blog. I also tend to switch steps around sometimes depending on how the project is going.

My next step after the first coat of poly on the lids and sides was to flip the box, put 2 coats of poly on, sanding with 400 grit paper in between coats and applying my label. I haven't invested in a branding iron yet so my solution is to use double sided carpet tape and a business card. I will find out how well these stand up to my kids carrying them around the house for a year or so and decide if I need to come up with a new idea. So far these seem very sturdy. The cards I bought have a nice glossy finish on them and we all know how strong carpet tape is.
Wood Rectangle Hardwood Gas Font


Once the bottoms have fully dried I flip them back over, re-sand and add another coat of poly
Wood Flooring Hardwood Wood stain Lumber


Table Wood Flooring Floor Wood stain


I wanted to share this picture with you also. It is a different project but since I am going over finishing a little, I felt that this is kind of important to know and may help you out. As you can see in the picture I have several kinds of wood laminated together and then sanded through. Each wood finishes differently and poses it's own challenges. In this case the poly likes to raise the grain in walnut. This needs to be sanded out and re coated as many times as it takes to get the finish you want. The important thing is that you have to sand everything else a little extra. The padauk will have a high gloss after just a couple of coats, while the walnut will take a few more. To keep it all even I sand down the other woods a little extra. Basically I make sure I take all of the glossiness away from the other woods until I have a uniform dulled look. I will try to capture this in a photo and maybe add it to the comments later. This is one of those times, I am sure someone has a better method or idea and I would love to hear them.
Wood Rectangle Font Pattern Bag


Thanks for joining me, I know I have said that at least every other post, but I truly mean it. I have learned a lot from your comments and from the process of trying to document how I do things. I have to think about what I am doing and why so that I can explain it and I think that doing this blog and helped me become just a little better in the shop.

Thanks again, the next stop will be the finished projects page. Enjoy the dust.

Joey
I'm wondering if several coats of sanding sealer before the topcoat would solve the issues with different types of wood and how they take the poly topcoat. Sanding sealer dries very quickly and may save time too. it's worth a try!
 

Attachments

#65 ·
Time for the wrapping paper!!!!!!!

Here is a sneak peak before I post the finished project. I want to thank everyone once again for joining me as I made these boxes. They will have more meaning for my wife and daughter than I can share here. They represent a once in a life time opportunity that they spent together. It is said that swimming with dolphins is one of the most healing things you can do for the spirit. I agree with this, but we cannot all swim with dolphins, so remember that making something for those you love, with all your heart can be just as healing.

And with that I will leave you with a picture and a wish.

The picture:
Brown Wood Motor vehicle Rectangle Wheel


And the wish:

I wish for you all to remember what Christmas is about. It is about the act of giving with the expectations of nothing in return.

Happy Holidays to all and I will see you next time.

Thanks you so much for letting me share my experiences with you.
 

Attachments

#66 ·
Time for the wrapping paper!!!!!!!

Here is a sneak peak before I post the finished project. I want to thank everyone once again for joining me as I made these boxes. They will have more meaning for my wife and daughter than I can share here. They represent a once in a life time opportunity that they spent together. It is said that swimming with dolphins is one of the most healing things you can do for the spirit. I agree with this, but we cannot all swim with dolphins, so remember that making something for those you love, with all your heart can be just as healing.

And with that I will leave you with a picture and a wish.

The picture:
Brown Wood Motor vehicle Rectangle Wheel


And the wish:

I wish for you all to remember what Christmas is about. It is about the act of giving with the expectations of nothing in return.

Happy Holidays to all and I will see you next time.

Thanks you so much for letting me share my experiences with you.
Happy holidays to you and yours… look forward to more fantastic projects in the future…
 

Attachments

This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Top