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Unity

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Project by kdc68 posted 12-06-2015 04:11 PM 1595 views 16 times favorited 17 comments Add to Favorites Watch

Oxford dictionaries defines the word Unity as “the state of being united or joined as a whole”. I tried to interpret that definition with these four boxes. This year has been tough; my family is experiencing difficult times. These were made for my mother, my two younger brothers, and myself for Christmas. The message I’m sending to the four of us is “we are in this together”.

Going from a photo of a box I seen on the internet , I drew out my patterns, then made templates from 1/4” hardboard.

I was saving a beautiful piece of figured cherry for something exactly like this. I laid out the fronts and backs of each box onto the cherry board in sequence. As seen in the photos, the sequence is left to right. Luckily the board was large enough to also yield the eight side pieces.

I wanted contrast for the lids and legs. They are made from a single piece of walnut. The straight grain and the rich color in this piece of walnut was perfect for contrast. As I did with the cherry, the lid of each box was laid out onto the walnut board in sequence from left to right. All 16 legs were cut from this single board as well.

The box bottoms are cherry veneered 1/4” plywood. They were ripped from a wider sheet into a single strip and crosscut to length in sequence from left to right.

I like the look of amber shellac on walnut and I like the look of garnet shellac on cherry. The compromise for the finish is 1:1 ratio of dewaxed amber and dewaxed garnet shellac. I made a separate batch of the amber and a separate batch of the garnet both equal in volume and both a 1lb. cut, then mixed the two together. I applied the shellac mix in two light coats. I then top coated in lacquer, first in gloss for clarity, then in satin for sheen. Four coats of lacquer in total.

The method of construction is mortise and tenon. Tiny 1/8” wide by 1/4” mortises were milled into the legs with a 1/8” bit on the router table. Photo below
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The corresponding tenons were milled on the table saw with a box joint saw blade set. Photo below
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Tenons were cut slightly fat, and then sized to a snug fit into each mortise with a shoulder plane. First dry fit is in the photo below
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Chamfers were cut on the tops on the legs next. Photo below
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More milling and shaping completes the legs, fronts, backs, sides, and bottoms. I used a taper jig to mill a taper on two sides of each leg. The jig is seen on the saw. Next to do are all the lids. Photo below
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It was necessary to notch the bottoms. Photo below
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Another dry fit before moving on to milling the lids. Photo below
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I made a lid template from scrap. As I did with the fronts, backs, and sides I used a pattern bit on the router table to shape the lid. Photo below
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Lid fresh off the router table and dry fitted to the box. Spacers cut from scrap are inside the box supporting the lid during this dry fit. Photo below
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All lids fresh off the router table. Some hand work is next to complete the desired fit on all the lids. Photo below
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I used a piece of 1/8” brass rod as hinges. Once I determined the location of the brass rod on the box assembly, I ganged the sides of each box together and drilled through holes of the drill press. Photo below
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I used a 6” steel rule and shims from my dado stack to align the lid into position and clamped in place. I bravely drilled the corresponding holes into the lid with a hand drill and by eye. The dado stack shims are thickness of #6 brass washers that I used between the lid and box side in conjunction with the brass rod as the hinge mechanism. Photo below
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Another dry assembly was necessary for the hinge install and final lid fit. I tweaked each box in the dry fit to achieve an even reveal with the lid and clamped in place. It was necessary to roundover the back edge of the top in order for it to clear the back and create a stop. All the lids open a couple of degrees passed 90. Later on I epoxied the brass rods into place and cut flush to the box sides. Photo below
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I finished them off by fitting the insides with sand colored self- adhesive backed felt. Photo below
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-- Measure "at least" twice and cut once





17 comments so far

View Ken90712's profile

Ken90712

16954 posts in 2651 days


#1 posted 12-06-2015 04:29 PM

Sorry to hear about the difficult times you and your family are going through this yr. Your gift idea is perfect reminder of sticking together as a family. We went through this last yr, with a family loss. I just had my pops out here from Michigan for 16 days it was incredible. This is the 2nd time we got to spend everyday in my woodshop. These times are priceless.

Your build was perfect. Love the photos and description of your process on the different steps. The wood colors are great. Congratulations on the great gifts.

-- Ken, "Everyday above ground is a good day!"

View doubleDD's profile

doubleDD

5221 posts in 1505 days


#2 posted 12-06-2015 04:41 PM

Nice step by step description on some great boxes for the family. Almost makes me want to make a couple. Hope things start to get better.

-- Dave, Downers Grove, Il. -------- When you run out of ideas, start building your dreams.

View kdc68's profile

kdc68

2526 posts in 1739 days


#3 posted 12-06-2015 04:42 PM

Thank you Ken for the kind words.

-- Measure "at least" twice and cut once

View kdc68's profile

kdc68

2526 posts in 1739 days


#4 posted 12-06-2015 04:43 PM

Thanks Dave. Nineteen days left so there’s still time !

-- Measure "at least" twice and cut once

View Randy M.'s profile

Randy M.

81 posts in 713 days


#5 posted 12-07-2015 02:11 AM

Very nice boxes and write up on project actually one of the best I have seen. Hope your family has a great holiday and I know everyone will enjoy these. Woodworking is a great hobby to eliminate stress I know it has helped me considerably.

-- Do it with your heart in it.........

View a1Jim's profile

a1Jim

115202 posts in 3039 days


#6 posted 12-07-2015 02:29 AM

Great looking boxes and super photo work up. I hope your difficult times are over. I wish you and your family a wonderful holiday season.

-- http://artisticwoodstudio.com Custom furniture

View kdc68's profile

kdc68

2526 posts in 1739 days


#7 posted 12-07-2015 09:38 AM

Thank you Randy for your response. You and I share the same feelings about woodworking.

-- Measure "at least" twice and cut once

View kdc68's profile

kdc68

2526 posts in 1739 days


#8 posted 12-07-2015 09:40 AM

Thanks for the compliment Jim. I also wish you and yours a wonderful holiday !

-- Measure "at least" twice and cut once

View kdc68's profile

kdc68

2526 posts in 1739 days


#9 posted 12-07-2015 09:43 AM

Thank you LJ’s for the Daily Top 3 !

-- Measure "at least" twice and cut once

View MrLaughingbrook's profile

MrLaughingbrook

92 posts in 1429 days


#10 posted 12-07-2015 11:32 AM

Thank you. I’m working on a set with brass pin hinges right now… During dry fit my hinges squeak and creak. Did you lubricate the pin hole in the top, then glue pin in the sides?

-- MrLaughingbrook

View Roger's profile

Roger

19867 posts in 2266 days


#11 posted 12-07-2015 02:14 PM

Gr8 looking boxes. Nice build along pics also. Things will get better.

-- Roger from KY. Work/Play/Travel Safe. Keep your dust collector fed. Kentuk55@yahoo.com

View kdc68's profile

kdc68

2526 posts in 1739 days


#12 posted 12-07-2015 10:15 PM



Thank you. I m working on a set with brass pin hinges right now… During dry fit my hinges squeak and creak. Did you lubricate the pin hole in the top, then glue pin in the sides?

- MrLaughingbrook

v
Actually no I didn’t experience squeaks or creaks. During my first dry fit however, I had a couple that were a little harder to open than the other two. I took 600 grit sandpaper to all the pins and that helped. The next dry fit, they all opened and closed easily.
I used epoxy to adhere the pins to the sides once I was satisfied with how they opened and closed.
Good luck with yours and thanks for the post.

-- Measure "at least" twice and cut once

View kdc68's profile

kdc68

2526 posts in 1739 days


#13 posted 12-07-2015 10:16 PM

Thank you for the compliment Roger !

-- Measure "at least" twice and cut once

View majuvla's profile

majuvla

9120 posts in 2329 days


#14 posted 12-08-2015 07:28 AM

It realy deserves Daily top 3. Beautiful design – curves and tappered legs. Interesting joints indeed.

-- Ivan, Croatia, Wooddicted

View kdc68's profile

kdc68

2526 posts in 1739 days


#15 posted 12-08-2015 09:38 AM

Thank you for the compliment Ivan !

-- Measure "at least" twice and cut once

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