My wife asked me when I was going to make her a box to keep our business cards in when we travel. I had made a few boxes but never one upon request- especially from her. So I wanted this to be special. I went about making a bandsaw box in an unconventional way and I was having a problem with the hinge design. One night I had a dream of how to do it and wrote it down right away in the morning. Here are the steps I used to make the box using mainly the bandsaw and the scroll saw for one tough part.
I forgot to mention one thing. If you can’t see the complete picture- right mouse on it and click view image.
I had these two very figured pieces of spalted beech on my bench and had planned to make bandsaw boxes one day. Here is what I started with:
I cut it to make an interior of 2 1/4×2 1/4×3 5/8 with 5/8” on top, front and both sides and 1/4” bottom and 5/16” back.
Then I cut off the top and bottom:
Then I cut out the inside by making straight cuts to remove the back and mitered cuts to remove the front.This was so there was no seam showing on the front when I put it back together. I saved the inside block for another project:
I drilled the back for the hinge pins before I cut it apart:
Then I had to use the scroll saw to create the hidden integral hinge:
The scroll saw was the thinnest blade I had but it did leave a space that I had to shim with some .017” washers to remove any side play for the lid.I punched out two of them using some aluminum flashing materila and cut two 1/8” steel pins for the hinges:
With a little sanding for clearance, the hinge works:
the back, front and sides were then glued together with a block to hold the back parts straight. I sanded the inside of these parts except in the area where I cut them apart. They mated great there.
The top and bottom were glued on and I did a final cut on the jointer and miter saw to make sure the assembly was square.
I don’t have any more pictures of the next operations, but I next cut the top loose along the hinge line all the way around and began shaping the block by cutting a radius on the top, then the front and then the sides and I blended all the surface together on the belt sander and orbital sander.
I had this rectangular block left from the center and it was so pretty, I made an obelisk out of it and will post a short blog on how I do them next.
-- Jim Jakosh.....Practical Wood Products...........Learn something new every day!!