|Project by robscastle||posted 10-04-2015 01:58 AM||1641 views||5 times favorited||14 comments|
You may have seen Kiefers first Harvest box he made.
I was so inspired by the work and presentation I decided to do one myself.
The timber I used was off cuts from a friends house he was building and I had been asked to doing some electrical work.
As I was leaving I spotted some Blackbutt flooring offcuts in a pile of rubbish he said I could have as much as I liked so I gathered up about eight pieces.
Four pieces I used in the lid and,
The other four in the box base.
First up I sawed off the edge sections of the tongue and groove for the lid parts and both sides of the T&G for the box sections.
Once I had the lid complete I determined the box size using the Fibanachi method and trimed the lid to suit the box frame.
The lid retains the original T&G in the center sections and was thicknessd to remove dings and defects only, so the thickness was determined by surface finish being defect free.
The box frame unfortnately doesnt have the 7 deg signature dimension as per Klaus’s, which was a pitty as I was keen to try this construction method out.
The final thicknessing prevented this, so the sides are just parallel.
The lid stand off is a frame simply made from remaining off cut pieces
I studied Klaus’s pictures and rebated the top and rabbeted the bottom, I used an additional piece of Ply for the base.
Cut 45 deg angles on the frames and glued everything together.
The handle I laminated using the bandsaw and glued it back together using the caul I had.
The construction of the handle was quite a dielemma as I didn’t know at the time how it was done, later via a message I found out, (quite an interesting process by the way, well worth checking out) anyway continuing on, I wanted to retain the original stress relief grooves in the timber of the handle for authenticity but it looked ugly when I finally finished it so sanded it all off again with a linisher.
The handle is attached via stand offs and secured carefully with 2×40mm screws from the underside of the lid
The Mortice trims
The mortice trim are simply off cuts sanded at 45 deg all round then cut off with the band saw, a very fiddly job for somebody with poor eyesight I tell you, I lost quite a few in the process, never found where they went to!
Then simply a matter of them being glued in position using awl marks to key them in.
Simply four offcuts tapered to suit, (an opps was done here… try not to notice I mis oriented one foot on each side)
First up sanding then sanding then even more sanding, I started at 80 grit finished with 320 grit
This is what it looked like after I was finished the sanding work.
I then used a scraper to prep the surface and remove any glue residue.
Then it was onto the polishing wheel, where here I used white compound and set to work
Everything polished up well and I even managed not to loose any parts this time.
I used black flocking.
The External surfaces.
After the polishing I used a cotton wheel and Shellawax to produce the final sheen.
As with Kiefers Post I needed to maintain every attempt of his professionalism so took lots of photos around the house to produce the effect shown in the 6 feature shots.
The rest are raw as construction shots.
It would be remiss of me not to acknowledge Kiefers inspiring work which prompted my project
Its greatly appreciated Kiefer… and Thank you for your work and guidance during this KKO Box!!
We have been invited back for the house warming so the box will become a gift for Michael and Maxine’s new home.
-- Regards Robert