| Project by Don | posted 712 days ago | 2406 views | 1 time favorited | 35 comments | ![]() |
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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.canterburybaptist.org/






























35 comments so far
Douglas Bordner
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3316 posts in 815 days
posted 712 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
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3494 posts in 731 days
posted 712 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
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275 posts in 1079 days
posted 712 days ago
Don
I think the box has a better chance than the mallet! Well done.
t.w.
-- Bandsaw Box Plans
MsDebbieP
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13437 posts in 912 days
posted 712 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. :)
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
john
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973 posts in 1133 days
posted 712 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 http://www.extremebirdhouse.com ....http://community.webshots.com/user/cranbrook2
Karson
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21155 posts in 1152 days
posted 712 days ago
Don Great little Box. Good choice.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Thos. Angle
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3949 posts in 714 days
posted 712 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
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2465 posts in 745 days
posted 712 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
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544 posts in 723 days
posted 712 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.
-- Jojo, shopless in Kyoto · http://www.japanese-woodworking-tools.com/ · http://twitter.com/japanesetools
Don
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2588 posts in 928 days
posted 712 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.canterburybaptist.org/
Bill
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2548 posts in 913 days
posted 712 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
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4573 posts in 1062 days
posted 712 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
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1808 posts in 837 days
posted 712 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
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4892 posts in 788 days
posted 712 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
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120 posts in 833 days
posted 712 days ago
Looks great Don!
jockmike2
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5707 posts in 998 days
posted 711 days ago
Absolutely beautiful and ingenious. You’ve outdone yourself. Way to go. Great looking box. Buds, mike
-- Mike. mwurm13@yahoo.com
WayneC
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5774 posts in 848 days
posted 711 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
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1770 posts in 748 days
posted 711 days ago
I support your move to enter the box!
-- Dorje (pronounced "door-jay"), Seattle, WA
Jojo
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544 posts in 723 days
posted 711 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.
-- Jojo, shopless in Kyoto · http://www.japanese-woodworking-tools.com/ · http://twitter.com/japanesetools
MsDebbieP
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13437 posts in 912 days
posted 709 days ago
((complicated-er and complicated-er becomes the rules))
A lovely box—both ways.
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
Greg3G
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769 posts in 837 days
posted 709 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
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1191 posts in 1058 days
posted 709 days ago
Great job Don! I admire your dedication to the rules. Best of luck in the contest.
-- Rob (A) Waxahachie,TX
cajunpen
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5952 posts in 817 days
posted 705 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
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3341 posts in 1078 days
posted 702 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
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1808 posts in 837 days
posted 695 days ago
Great job Don. Congratulations. I love this box.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
PanamaJack
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4449 posts in 829 days
posted 695 days ago
Just a wonderful way to show off you abilities with this box Don. It is just fantastic! Thanks.
-- Carpe Lignum - Seize The Wood,
Joel Tille
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214 posts in 995 days
posted 695 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
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181 posts in 764 days
posted 695 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
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2588 posts in 928 days
posted 694 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.canterburybaptist.org/
Karson
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21155 posts in 1152 days
posted 694 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.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Lee A. Jesberger
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3494 posts in 731 days
posted 694 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
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2588 posts in 928 days
posted 694 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.canterburybaptist.org/
Karson
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21155 posts in 1152 days
posted 693 days ago
Don great replacement with the new bottom.
-- Karson Southern Delaware karson_morrison@bigfoot.com †
Blake
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2560 posts in 625 days
posted 500 days ago
This is really nice, Don! I love how the lid is part of the box-joint.
-- Check out my new website! http://www.blakeweberwoodworking.com
abie
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80 posts in 522 days
posted 385 days ago
WOW…...
-- Bruce