Clear Epoxy - Used Shell, Dovetailed Box

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Project by Mike_from_Buffalo posted 10-14-2014 04:04 PM 1646 views 3 times favorited 2 comments Add to Favorites Watch

I recently got married, this is a box that I made as a gift for my best man. After it was complete I filled it with some ammo.

I saw some other projects on here that encased items in clear epoxy resin, there was a table with beer caps that impressed me in particular ( So I thought this would be a cool idea for a box top. My best man is an avid hunter so i thought to incorporate some used shells in a pattern encased in epoxy.

So here’s what I did:

Took some 1/2 birch plywood and veneered some walnut onto both sides, this would be the top and bottom panels.

Made the box from Ash, used a rockler dovetail jig to make the pieces.

I left 3/8” from the top of the upper panel to the top of the side pieces, bullet shells were cut such that 1/4” of them were sticking out of the top. I cut the bullet shells on a table saw using a jig (USE FULL FACE PROTECTION!) (ask me how I know that now. lol. )

I then filled the top with 2 part epoxy (from envirotech I believe) I filled it in 3 stages, 1/8” at a time. I think if I ever do this again I will just go with one fill. The bubbles show up clearly in the pictures cause of the flash. I used a torch, and that got all the bubbles that went to the surface. But it seemed that the bubbles stuck to the previous layer. I should have gone in there and tried to get them out with a pin or something. live and learn. They aren’t really that visible. And the surface is sooo smooth.

Added SOSS hinges. Had a little oops when my router template slipped, right at the end of the dang project.
Added a small mortised in chest lock from lee valley.
Finished it with 3 coats of spray on shellac, then Briwax and a polishing pad. Super smooth, super easy finish.

-- Mike from Buffalo "A man spends the first half of his life learning habits that shorten the other half of his life."

2 comments so far

View Gene Howe's profile (online now)

Gene Howe

8087 posts in 2847 days

#1 posted 10-14-2014 04:46 PM

When you have a re-commitment ceremony, I volunteer to be your best man!

-- Gene 'The true soldier fights not because he hates what is in front of him, but because he loves what is behind him.' G. K. Chesterton

View Mike_from_Buffalo's profile


101 posts in 1303 days

#2 posted 10-14-2014 07:05 PM

Thanks Gene!

-- Mike from Buffalo "A man spends the first half of his life learning habits that shorten the other half of his life."

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