| Project by Don | posted 932 days ago | 2749 views | 2 times favorited | 35 comments | ![]() |
![]() |
I’ve made up my mind.
Although I like the Mallet I made with glueless joinery, I think I like the small box more. After all, I can’t claim to be a lover of small wooden boxes without being prepared to be evaluated as a box maker.
In theory, I could disassemble this box quite easily. The only thing that holds it together is the bamboo pins that are snuggly pressed into holes. Nothing is wedged because as I quickly discovered with my first attempt, the wall strength of 5/16” wood does not accommodate joinery under excess tension – it simply splits.
The dimensions of the box are: 8 5/8 wide x 5 1/2 deep x 2 3/4 high.
So I came up with the method described here to hold the box together. The pins won’t fall out of their own accord. I would have to pull them out in some way, because there is enough surface tension to hold them in place. I played with the idea of a “Pagoda” type lid handle, but a) I didn’t like the look, b) I wasn’t sure I could design a joint that would hold and c) the natural way to open the box is by the “tabs” at the front of the lid.
Finally, I’ve finished the box with three coats of Danish Oil and three coats of sprayed lacquer on top of a single coat of Tung Oil. The two pictures above were taken with artificial room light and have distorted the color slightly. Although their appears to be a sheen on some surfaces, I’ve actually rubbed out the finish to give it a slightly flat but deeper finish.
Late Change: Karson stated the following here ”No one has asked, but I’ll bring it up. In my mind no plywood, because that is glued. The constructor of the project might not have glued it but it is a joint and it does have glue.
I don’t want to be a stickler about this, but, I think that is what the description of the contest states.
So that means no veneered projects either, in my mind.”
I panicked a little; the base of my box was birch ply.
I must confess, that the idea that plywood was a raw material that had been laminated, hence glued, had never dawned on me, and at first I thought it was being a little pedantic. But as I lay awake in bed last night it suddenly dawned on my that this was one of the hidden benefits of my style of glueless joinery. My retainer pins for the bottom panel were held there by the tightness of the fit. But with a pair of pliers, they could easily be extracted, which is what I did. Voilà! I simply replaced my ply base panel with a 4mm piece of solid Tasmanian Myrtle.
The third picture shows the new solid wood panel. I’m not changing the center picture, because it helps to verify I’ve done so because of the difference in color between the Birch ply (center pic) and the Tasmanian Myrtle (last pic).
I made the solid panel slightly smaller than the ply panel to accommodate expansion. Being a floating bottom, the base will exert no pressure against the walls of the box.
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/































35 comments so far
Douglas Bordner
home | projects | blog
3473 posts in 1035 days
posted 932 days ago
Good choice, Oh lover of small wooden boxes. But I am glad you shared the mallet with the foxed tenons, as I have never seen that style of joinery before. Although I have done some garden projects, and they see the light of day everyday, they will likely not be seen through the light of a monitor screen. Maybe the next challenge.
-- "Bordnerizing" perfectly good lumber for over a decade.
Lee A. Jesberger
home | projects | blog
3781 posts in 951 days
posted 932 days ago
Hello Don;
Don’t you hate it when you have to chose. It’s like getting married all over again. LOL
Nice choice.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
TonyWard
home | projects | blog
285 posts in 1299 days
posted 932 days ago
Don
I think the box has a better chance than the mallet! Well done.
t.w.
-- Bandsaw Box Plans
MsDebbieP
home | projects | blog
15086 posts in 1132 days
posted 932 days ago
(Lee: I’m sure there is a story behind those words!!)
The box is lovely – I especially like how you made the lid mimic the side pieces, tying it all together.
Nicely done and I guess a lover of small boxes should enter a small box into the challenge. :)
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
john
home | projects | blog
1364 posts in 1353 days
posted 932 days ago
Nice work once again Don.
The corners kind of remind me of my birdhouses but then again everything reminds me of birdhouses. lol
-- John in Belgrave ,(Slideshow http://cid-69bce320c6d8b119.spaces.live.com/ (Website) http://www.extremebirdhouse.com
Karson
home | projects | blog
28894 posts in 1372 days
posted 932 days ago
Don Great little Box. Good choice.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †
Thos. Angle
home | projects | blog
4062 posts in 933 days
posted 932 days ago
a very unique approach. nice work. I especially like the look of the corners. great grain. thanks for the nice comments on my projects
-- Thos. Angle
TomFran
home | projects | blog
2593 posts in 965 days
posted 932 days ago
”Although I like the Mallet I made with glueless joinery, I think I like the small box more. After all, I can’t claim to be a lover of small wooden boxes without being repaired to be evaluated as a box maker.” - Don
Don, I agree with this logic. You have established yourself as a “lover of small wooden boxes” and in order to maintain consistency with this motto, you must stay with your choice of this “small wooden box.” ;^D
-- Tom, Surfside Beach, SC - Romans 8:28
Jojo
home | projects | blog
593 posts in 943 days
posted 932 days ago
Interesting design Don, I like the choice of the bamboo pins taking the place of the glue and the protruding fingers. It’s certainly a change from the machined fingerjoints that sport the indonesian-made little boxes that flood the market nowadays.
Pardon my ignorance but what exactly is a ’”Pagoda” type lid handle’. I can’t really visualize it… and it’s not that I don’t have any real scale pagodas to look at nearby! Now that I think there’s one of many down the street, half a mile away. :o)
I do agree with Tony and the rest: this is a better choice for a joinery challenge.
Don
home | projects | blog
2579 posts in 1148 days
posted 932 days ago
Jojo, perhaps using the term Pagoda was overstating my idea. I spent an hour shaping a piece of Ebony as a handle or knob, shaped with upcurved ends similar to the look of the roof-line of a Pagoda. My research indicated that most Pagoda roofs have more than one layer with the layers on top being smaller than the ones under them. Also, most appear to culminate in a small spire of some kind.
I came up with a shape that looked OK, but with the following problems.
My design difficulty, is that a lid is normally lifted from the edge opposite the hinge. This would dictate that the Pagoda-shaped knob be no more that 1/3 the distance from the front to the hinge, but preferably closer to the front edge. However, this flies in the face of the symmetrical nature of the Pagoda. Placing it anywhere but dead centre looked strange.
Also, a spire shape just doesn’t work well on a knob. And even if it did look OK, I wasn’t sure that I could come up with a glueless joinery idea that would both work and look right.
Hence I abandoned the concept.
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
Bill
home | projects | blog
2553 posts in 1132 days
posted 932 days ago
Bravo Don. I think you made the right choice. This box looks even better now with the finish.
-- Bill, Turlock California, http://www.brookswoodworks.com
oscorner
home | projects | blog
4566 posts in 1282 days
posted 932 days ago
I was unable to see your mallet, but I believe that your box is exceptionally well done and very interesting in its design and joinery. Congratulations!
-- Jesus is Lord!
Bob Babcock
home | projects | blog
1804 posts in 1057 days
posted 932 days ago
Good choice Don. I really like this box.
Good choice on not using the pagoda handle. It looks good on a lift top box, but a hinged box would make it look odd.
Good luck.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
mot
home | projects | blog
4900 posts in 1008 days
posted 932 days ago
Don, great box! Thanks for blogging it as well. I love a wooden box. I just have to bring myself to start makin them. I have all kinds of wood devoted to the box. I just haven’t pulled the trigger. I better get on it!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
Lboy
home | projects | blog
144 posts in 1053 days
posted 932 days ago
Looks great Don!
jockmike2
home | projects | blog
7903 posts in 1218 days
posted 931 days ago
Absolutely beautiful and ingenious. You’ve outdone yourself. Way to go. Great looking box. Buds, mike
-- Mike from Michigan - mwurm13@yahoo.com
WayneC
home | projects | blog
6335 posts in 1068 days
posted 931 days ago
Great box Don. I have a couple I made over the weekend to sand, finsih and post. OS, I belive the mallet is here
http://lumberjocks.com/projects/1951
-- We must guard our enthusiasm as we would our life - James Krenov
Dorje
home | projects | blog
1767 posts in 968 days
posted 931 days ago
I support your move to enter the box!
-- Dorje (pronounced "door-jay"), Seattle, WA
Jojo
home | projects | blog
593 posts in 943 days
posted 931 days ago
Got it Don, you’re absolutely right regarding your observations on the “pagoda”. Did a great job describing it too, I am able to “see” it perfectly and I think you did the right move discarding it… on this project. Now if your next box lid is hingeless that would be great to try.
MsDebbieP
home | projects | blog
15086 posts in 1132 days
posted 929 days ago
((complicated-er and complicated-er becomes the rules))
A lovely box—both ways.
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Greg3G
home | projects | blog
779 posts in 1057 days
posted 929 days ago
Beautiful Box Don. I agree with JoJo that you made the right choice on the lid. I love the grain pattern of your wood choice and the finish seems to bring it out well. Great work.
-- Greg - Charles Town, WV
RobS
home | projects | blog
1256 posts in 1278 days
posted 929 days ago
Great job Don! I admire your dedication to the rules. Best of luck in the contest.
-- Rob (A) Waxahachie,TX
cajunpen
home | projects | blog
5980 posts in 1037 days
posted 925 days ago
Good save Don, bet you were happy that there was no glue in the project, which allowed you to take it apart – remove the plywood – and “get legal” with the solid wood. Beautiful box too.
-- Bill - "Suit yourself and let the rest be pleased." http://www.cajunpen.com/
scottb
home | projects | blog
3409 posts in 1298 days
posted 922 days ago
Yes, a very nice box… the mallet was great too – and while I agree with the others on your choice of submitting the box for the contest – there is nothing wrong with working outside your comfort zone – not that I think any of your non-box projects really could be classified as such.
-- I am always doing what I cannot do yet, in order to learn how to do it. - Pablo Picasso -- http://blanchardcreative.etsy.com -- http://snbcreative.wordpress.com/
Bob Babcock
home | projects | blog
1804 posts in 1057 days
posted 915 days ago
Great job Don. Congratulations. I love this box.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
PanamaJack
home | projects | blog
4454 posts in 1049 days
posted 915 days ago
Just a wonderful way to show off you abilities with this box Don. It is just fantastic! Thanks.
-- Carpe Lignum; Tornare Lignum (Seize the wood, to Turn the wood)
Joel Tille
home | projects | blog
213 posts in 1215 days
posted 915 days ago
Congratulations on your finish Don. Good description of the process.
The one thing about this challenge was that so many of us could learn more techniques we would probably never thought of. I liked you mallet also. Much better than the one I turned.
-- Joel Tille
furnitologist
home | projects | blog
194 posts in 984 days
posted 915 days ago
Hi Don…...........couldn’t be happier. Just clean and to the point of the challenge.
I loved the ability to bring her back into the pit for a quick change….......a great charge at the challenge.
Neil
PS…..I enjoy your writing style.
Don
home | projects | blog
2579 posts in 1148 days
posted 914 days ago
Thanks for all of the very encouraging comments.
I’m stoked that my entry even rated. Although I love small wooden boxes with a passion, I realize my box hardly compares to the two entries taking first and second. Frankly, I was a little embarrassed with my humble box when I saw these and other projects entered after mine. I’m glad I had the courage to enter mine when I did, because I would probably have not done so after seeing the other great entries.
This is a wonderful community of women and men and I count it a real honor that my small wooden box rated.
Thanks!
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
Karson
home | projects | blog
28894 posts in 1372 days
posted 914 days ago
Don Congratulation on your entry and the vote. It’s a great vote of confidence in your “I just love small wooden boxes!” boxes.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †
Lee A. Jesberger
home | projects | blog
3781 posts in 951 days
posted 914 days ago
Hi Don;
I guess you picked the right project, or did you?
Again, incredible work, Don.
Lee
-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com
Don
home | projects | blog
2579 posts in 1148 days
posted 914 days ago
I think so, Lee. I find it hard to believe that a project with a single joint would even rate.
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
Karson
home | projects | blog
28894 posts in 1372 days
posted 913 days ago
Don great replacement with the new bottom.
-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware karson_morrison@bigfoot.com †
Blake
home | projects | blog
2965 posts in 845 days
posted 720 days ago
This is really nice, Don! I love how the lid is part of the box-joint.
-- Check out my website! http://www.blakeweberwoodworking.com
abie
home | projects | blog
127 posts in 742 days
posted 605 days ago
WOW…...
-- Bruce