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Guest of Honor gift for Officer Candidate School birthday ball

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Blog entry by M1ni0n posted 1713 days ago 940 reads 0 times favorited 13 comments Add to Favorites Watch

OK, I am going to try my hand at keeping a blog going for the current big project I am doing with the help of my Marines. We are building a box that will hold a small tray with a flag case. The flag case will house a flag flown ot Officer Candidates School headquarters in Virginia. I currently have the Google Sketchup drawing and plans done. We have already began milling our lumber and building our jigs required to construct this project. I will post what I have so far. Hopefully I am better about documenting the progress od this project as that is the whole reason I am starting the blog entry. Enjoy!

-- Jason



13 comments so far

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M1ni0n

46 posts in 1959 days


#1 posted 1713 days ago

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M1ni0n

46 posts in 1959 days


#2 posted 1713 days ago

And as always they did not work as planned. You can click the link and it will take you to the pics, but I need to work on getting them so you do not have to click the link. Hopefully I can figure this out.

-- Jason

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M1ni0n

46 posts in 1959 days


#3 posted 1713 days ago

-- Jason

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M1ni0n

46 posts in 1959 days


#4 posted 1713 days ago

Ok, so I go from one problem to another. First I post nothing but links. then I post a half of a pic. I did what the tutorial said to do for photobucket and I end up with half of a picture. If there is anyone out there that has some insight for the not so smart guy, me, I am eager to listen.

-- Jason

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jack1

1910 posts in 2632 days


#5 posted 1712 days ago

Looks like a great plan. Don’t worry about the pics. If you can get them on a program like I-photo or something, you should be able to upload…

-- jack -- ...measure once, curse twice!

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M1ni0n

46 posts in 1959 days


#6 posted 1712 days ago

Here we go again. Lets see if this pic works.

-- Jason

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a1Jim

112002 posts in 2182 days


#7 posted 1712 days ago

Looks good

-- http://artisticwoodstudio.com Custom furniture

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M1ni0n

46 posts in 1959 days


#8 posted 1707 days ago

Well I finally have some more pics. I have already gotten some of the not so exciting stuff done. Milled the lumber, cut to dimension, and prepared the ends of the box sides for the box joint. Just to back track a little, we chose to use Morado (aka Bolivian Rosewood) as the wood for the main box. Then we are using Quartersawn Sycamore for the interior components (flag case and tray) and the accents on the box joints. Finally, there will be minor accents on the interior components that will be made of Cherry. I know, sounds like a bunch of crazy combinations, but it is the color combinations that we are looking for.

Well here are some of the pics I managed to snap before I got too far along. Sorry for the quality, they were done with my phone.

Dry fit of the box joint prior to glue up

view of box joint finger prior to glue up

inside view of the dry fit

Quartersawn Sycamore board used for interior compontents

Questions and comments are always welcome. Thanks!

-- Jason

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M1ni0n

46 posts in 1959 days


#9 posted 1707 days ago

Here are the final pics I have for this evening. These are some quick pics of the box getting glued up. I know, nothing really exciting, but what we went through in hair loss, this was a big moment. We finally got the box into a box. It’s not really that we are doing a difficult joint, it is more that the wood we are using was $11.50 a board foot. Do not want to make too many mistakes. Well enjoy and I hope to have some more updates tomorrow.

Box o clamps

close up of box o clamps

interior view of box in clamps

As you can see we are definately not afraid to use all kinds of clamps that may not be meant for the job. But use what you got and remember that you can never have enough or the right kind of clamps.

Jason

-- Jason

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M1ni0n

46 posts in 1959 days


#10 posted 1706 days ago

Well not much done this morning. I got mad and can’t work when I am mad about something. I tend to make more mistakes. But atleast I did not get mad about this project. I got made about another one that I was doing. Oh well, win some and lose some.

The box came out of clamps this morning and I began sanding the proud pins down in the corners. I am taking the whole box down to 150 grit before we do anything else with the box. Now it is time to start working on the interior tray and flag case.

I almost forgot, the next step for the joints is we have to cut spline joint slots for the horizontal pieces of sycamore to complete the overall look that we are going for in the box joint.

front view of box before sanding

side view of box before sanding

view of sides that have been sanded

close up of sanded corner

Jason

-- Jason

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M1ni0n

46 posts in 1959 days


#11 posted 1705 days ago

Well I am a few more steps farther as of this morning. I have the whole box sanded to 150 grit. I routed the rabbit into the bottom of the box that will allow the bottom to brad nailed into once it is complete. I also have everything laid out for the remaining peices. I will begin cutting that up tomorrow morning.

On another note, I was told that this Morado can possibly be an irritant when it is being worked. I was not really worried about that becuase I read the same thing about Paduak. The Paduak never bother me. Well joy to the world because this Morado is making me break out in small rashes. Lucky me. Thankfully it is not too bad but it is annoying.

Question and comments are always welcome. Enjoy!

Jason

close up of bottom rabbit

close up of bax sanded to 150

layout of remaining lumber

close up of layout on remaining lumber

-- Jason

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M1ni0n

46 posts in 1959 days


#12 posted 1704 days ago

Well today I got the lid pieces cut out, all of the dados cut into the frame and glued up. It is hanging out in the band clamp for the night. We also got the tray frame cut with the finger joints and glued up. I am not so happy about it because the finger joints did not come out the way they should have. I hope no one will notice. I think we did a good job hiding some of the mistakes. But anyway it is done. We just need to cut the rabbit into the bottom so we can place the hardbaord in.

Well here are the pics. And anyone that can help with better ways to cut finger joints I am all ears.

finger joint close up

tray frame in the box

lid in the band clamp

-- Jason

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M1ni0n

46 posts in 1959 days


#13 posted 1697 days ago

Ok, it has been a few days since I have last posted anything and I have pictures of things that I did over the weekend that I still need to post. I did not even think to take pics today as I was more busy working then taking pictures.

These pics show the work done on the tray handles. I sketched out a handle that I liked then made a templet of that. Then I rough cut the handles out of cherry, oversized. Flush trimmed them and then installed them on the tray. Overall I am relatively pleased with the outcome. I did make some minor mistakes. I did router out the mortise a little big, but not a huge issue. I also am not a perfectionist on the scroll saw, so the inside cut on the handle is less than perfect. And it is really hard to sand the saw marks and such on the inside of the hole of the handle. But hey it is hand made, right???

Enjoy the pics!

Jason

pic of the handle and the tray 1

pic of the handle and tray 2

handle glue up 1

handle glue up 2

-- Jason

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