Looking good so far. Now its time to mangle the pretty box up with hardware.
I used a jig and routed out the quadrant hinge form.
Which fit nicely.
Only to provide me a box with a 3/16 offset the first time around. I assumed I messed up the jig, so I planed the top and bottom flat again, and re-read the manual before attacking some scrap wood. 3/16th again.
A few emails back to the manufacturer, and I got a new one. (Beall, best service in the biz!)
Now, the next round isn’t perfect, but its within a whisper of perfect.
Then I went and proceeded to mangler the heck out of the mortise for the lock, blowing a HUGE hole in the front of the box. I didn’t take any more photographs at this point, because I was so supremely angry at myself I ran out of the shop and didn’t go back until I cooled down (~3 beers, followed by 2 weeks out of the shop did it.)
I decided mistakes happen, and anything is fixable. I like to inlay, so I pulled out my little whiteside kit, and decided to make an inlay to cover up my goof. ooh wait. I meant design element. I PLANNED THIS! YES, THATS THE TICKET!
And its a jewelry box for my wife, so I’ll use a heart shape, which bears absolutely no relation to the shape of the aforementioned blowout, which as I remind you, never happened.
I start with cheap 1/8th hardboard as I play with template sizes. I have no symmetry skills, so I tape 2 pieces tightly together, and pass em over the jointer. Follow up with some light spindle sanding.
Then unfold and glue together. Ta-da!
First, the top of the blowout is real thin (the bottom blew entirely through to the front of the box, so before I inlay, I mix up a dixie full of 5 minute epoxy and reinforce the heck out of the blowout. I tape over the big hole in the front, and slather it on.
I also managed to completely mis-align the retaining bar of the lock in the top half. whittle some sticks, slather glue, and …
And since I re-mortised the bottom after the bad offset, I also need to fix holes there too….
I always transfer my cheap hardboard inlay patterns to plexi once I get a size and shape I like completed. Just takes a pattern bit on the router table. Then I tried it out the plexi pattern on some scrap maple a few times.
Fitted glued and smoothed. You can’t even tell there was a blowout. Which, if you recall, there wasn’t. So stop saying there was!
After a lot of double checking, I drilled a near perfect hole for the key. Heck, even I get lucky sometimes.
Phew, enough for now!