| Project by GaryK | posted 836 days ago | 4304 views | 25 times favorited | 50 comments | ![]() |
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Well, this is my first attempt to build something without glue. To allay any
suspicion that any glue or mechanical fasteners were used in the construction I
have included a blow by blow of the construction process. 100% wood with NO GLUE used at all.
The other reason for showing the construction is to show some of the ideas I came up with.
One of the methods I came up with I have never seen used before.
All the methods presented here can be applied to larger projects. Just scale them up.
No special tools or fixtures were used in the construction.
Just a table saw, drill, and carving chisels for the top.
I think that the carved top gives it a distinctive look.
The wood used is pommele Sapele for the outsides of the box, and mahogany for the
inner panel for the lid, as well as the carved panel. The hinges are made from
swiss pear.
I have decided to add some contents for my box. This project is to display joinery
without glue. Therefore at the end of this listing I show some of my favorite samples.
To start with, the following picture shows everything fit together before any
pegs were used. The reason I show this is to display how tight everything
fits. The bottom panel is an exact fit to keep everything square. Same with the
two panels in the lid.
The next two pictures show the construction of the panels in the lid. The first
shows the panel that I will use to peg in place to hold everything together. The
second picture shows the panel which is rabbited around the perimeter to allow
it to be installed flush. This is actually my first attempt at carving a panel
like this. If I had screwed it up I would have put something else there :-)
Below are the pegs that I used to hold the hinges and the lid together. I used
the same method a couple of years ago to hold the head on a mallet I made. I
always call it a blind wedge tenon, but then I heard it called a foxed tenon on
this website. How it works is the wedge hits the bottom of the hole and as you
beat in the peg the wedge will expand the end of the peg wedging it into the hole.
It holds so well that the only way I have found to remove them is to drill them
out.
The following two pictures show the hinge blocks pinned in. The hinge blocks are
made from swiss pear and are mortised into the lid for strength.
The following picture shows the first three pegs installed.
The lid completed with all 12 pegs in place.
The completed lid.
The next two pictures show the hinge assembly. These pins will be cut flush and
captivated permanently once the sides are pinned in place.
This picture shows the rounded edges which allow the lid to pivot. Note that
hinge blocks are rounded also.
Now to the sides. This method of pinning I have never seen used before. (if
someone knows what it’s called please let me know). This method kills two birds
with one stone. First the pins are installed at an angle. This will prevent
either side from coming loose. They can’t be pulled apart without drilling (I
know because I forgot to put the hinge pins in before I put the sides together).
The second thing will keep the pins themselves in place. The holes intersect
each other about 1/64". This means that once the first pin is in place it
partially blocks the hole for the pin coming in the other direction. This puts
tension on both pins preventing them from coming out.
This shows the over lapping holes.
The completed box with no finish.
A couple more angles of the completed box
This ended up being a pretty quick project. A couple of days to think about it.
Two days for the carving. Two days to build it, and another two to finish it
with my favorite water based dye and oil based poly. This one definitely made me
think out of the "box".
If for some reason you can’t see the pictures properly that can see them here:
http://www.arealnice.com/box/
The following shows some of my favorite joints. They are made from mahogany, maple
and swiss pear for the ‘keys’. They were vary hard to make this small and are much easier
to make larger.
Here is the collection
The first is my all time favorite joint. I am showing many views of it because it is hard to grasp
from a single photo. This is basically a decorative joint for columns since it is not keyed.
These joints are for joining peices end to end and are very nice joints.
This one is like a standard saddle joint but with keys instead of glue to hold it together.
The advantage it that you can take it apart if needed.
This is a scarf joint with two keys. This joint must be slid together sideways to be assembled.
This is another scarf joint but has the advantage of being assembled any way. A single key holds
everything in place.
These are truly beautiful joints, and I hope that you enjoy them as much as I did making them.
-- Gary, East TX -- The longest journey begins with a single step.































50 comments so far
oscorner
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4572 posts in 1189 days
posted 836 days ago
Gary, your work is exquisite and the details in the posting and pictures are most appreciated. It turned out…I can’t find the words…WOW!!
-- Jesus is Lord!
mot
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4901 posts in 915 days
posted 836 days ago
That’s just awesome, Gary! Thanks for the detailed views. I love the process and the outcome!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
Karson
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25274 posts in 1279 days
posted 836 days ago
Great construction and great box. Good Luck. But if I get mine completed your in trouble. LOL
-- What happens in the workshop stays in the workshop. No wait that doesn't sound right. Karson Southern Delaware karson_morrison@bigfoot.com †
DAN
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6396 posts in 861 days
posted 836 days ago
very impressive work. beautiful box.
-- work from your heart and your spirit will live forever
Douglas Bordner
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3415 posts in 942 days
posted 836 days ago
Holy smokes! Glorious box, and thanks for the blow by blow. Really cool joinery and stunning carving work.
-- "Bordnerizing" perfectly good lumber for over a decade.
Bob Babcock
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1808 posts in 965 days
posted 836 days ago
Very, very, cool Gary. Of course at this point I expect nothing less than the best from you. This is a great entry to the challenge and very true to the rules.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
TreeBones
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1558 posts in 902 days
posted 836 days ago
Most Excellent
-- Ron, Twain Harte, Ca. Portable on site Sawmill Service http://westcoastlands.net/Sawmill.html http://westcoastlands.net/SawBucks2/phpBB3
Aubster
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121 posts in 907 days
posted 836 days ago
Very nice craftmanship in this box, and the over all box is very elegant. good luck on the contest.
-- A man who moves mountains starts one stone at a time.
Don
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2590 posts in 1055 days
posted 836 days ago
Gary, congratulations! This is an exquisite example of glueless joinery at its best. Some very careful planning here and great execution. Thanks so much for sharing the details of your joinery methods. Finally, in case you were unaware, I just love small wooden boxes.
Best wishes!
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
MsDebbieP
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14090 posts in 1039 days
posted 836 days ago
the lid!!!
The box!!
The joinery!!
and the process photos/description
ALL well done!!
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Chris Davis
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549 posts in 861 days
posted 836 days ago
that is a great piece of work, thanks for the details.
-- Watch live video from our shop. http://wwbeds.com/live.htm
TomFran
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2501 posts in 873 days
posted 836 days ago
Gary,
Great work as always. It’s great to have guys like you here, who can show us “ordinary” folks how it’s done!
I really appreciate your taking the time to produce these process pictures with explanation.
-- Tom, Surfside Beach, SC - Romans 8:28
Greg3G
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770 posts in 964 days
posted 836 days ago
Gary,
Great use of the Fox Tenon…If I had more time to compete, that was going to be my method. I love the finish and the carving. Overall a great job. I am sure it will be cherished for years to come.
Karson, you have some competition now… ;-)
-- Greg - Charles Town, WV
Mike Lingenfelter
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457 posts in 992 days
posted 836 days ago
Very nice, excellent work!
-- http://theinquisitivewoodworker.com/
RobS
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1231 posts in 1185 days
posted 836 days ago
Incredible display of joinery, great job!
-- Rob (A) Waxahachie,TX
CharlieM1958
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7466 posts in 1097 days
posted 836 days ago
Great technique, Gary…. you really gave me some ideas to think about.
-- Charlie M. "Woodworking - patience = firewood"
Bill
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2562 posts in 1040 days
posted 836 days ago
A wonderful piece Gary, and even more wonderful when you know what was involved with making it. The story and pictures were a great help. Some day I will have to try something like this. You and Don have been inspirational on how to make a box without glue or mechanical fasteners. Well done to both of you.
-- Bill, Turlock California, http://www.brookswoodworks.com
GaryK
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9497 posts in 867 days
posted 836 days ago
Thanks for all your great comments, I appreciate them.
These little boxes are fun to build! I think that I will be making a lot more of them.
It’s something that doesn’t take weeks or months to make like most everything else
I make.
It will also give me a chance to use all the small pieces of exotic woods that I couldn’t
just throw away. (I get a nice piece of wood and I tend to save all the small scrapes)
Well Don, you’ve got a convert.
-- Gary, East TX -- The longest journey begins with a single step.
Thos. Angle
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4015 posts in 841 days
posted 835 days ago
Gary, I think you’ve out done yourself!! Thanks for the blow by blow. It will get some use at some point int he future. Great job and thanks
-- Thos. Angle
Greg Mitchell
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1383 posts in 947 days
posted 835 days ago
Beautifully done Gary. Great job all the way around.
-- Greg Mitchell--Lowell, AR--gdamitchell@sbcglobal.net
woodspar
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705 posts in 978 days
posted 835 days ago
Wow Gary, thanks for posting the how to photos!
-- John
TonyWard
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284 posts in 1206 days
posted 835 days ago
GaryK
Well done!
As Don as suggested it is a competition, in this Category, of three box makers (so far) ~ I look forward to seeing a flood of other entries within the next 4 days !!!!!!!
-- Bandsaw Box Plans
scottb
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3391 posts in 1205 days
posted 835 days ago
Nice box. Thanks for sharing the construction process. Nothing like having to undo part of it as a reassurance everything will hold.
4 more days for the contest – oops – I best be getting busy!
-- 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/
Obi
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2191 posts in 1115 days
posted 834 days ago
Definately looks like a winner.
-- http://ye-olde-cabinet-shoppe.com/
Joe_F
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5 posts in 846 days
posted 833 days ago
Beautiful, Gary.
Bob Babcock
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1808 posts in 965 days
posted 833 days ago
This has been great to see Gary. I love the idea of storing the joint examples in there. They are beautiful. Fantastic job all around.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Don
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2590 posts in 1055 days
posted 833 days ago
Gary, I would also like to see seperately the two pieces that make up the joint.
Very interesting.
Best wishes.
-- CanuckDon "I just love small wooden boxes!" http://www.hilsbiblechurch.org/
Thos. Angle
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4015 posts in 841 days
posted 833 days ago
I just read the new addition, you just keep raising the bar. You may be the next Tage Frid. Keep at it.
-- Thos. Angle
Sawhorse
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279 posts in 1318 days
posted 833 days ago
Beautiful work, great ideas and the tutorial was excellent…
-- Sawhorse - Sulphur Springs, TX - www.sawhorseworkshop.com
scottb
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3391 posts in 1205 days
posted 833 days ago
Wow… someone who literally made “wood joinery” for the competition. and beautiful ones at that. Looks like i’m not the only lateral thinker here ;)
-- 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/
Drew1House
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425 posts in 966 days
posted 833 days ago
just hand over the prize and lets move on to the next contest…
WOW
Drew
-- Drew, Pleasant Grove, Utah
GaryK
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9497 posts in 867 days
posted 833 days ago
Don – When I get the chance I will take pictures of the other joints separated. I didn’t
do that because they are kind of easy to visualize unlike the first one.
-- Gary, East TX -- The longest journey begins with a single step.
MsDebbieP
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14090 posts in 1039 days
posted 833 days ago
oh my goodness !!!!
lol and I’m still working on a straight line.
Amazing
-- ~ Debbie, Canada (http://www.execulink.com/~yohan)
Mike Lingenfelter
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457 posts in 992 days
posted 833 days ago
Absolutely incredible. I’d love to see how you laid out and cut some of those samples.
-- http://theinquisitivewoodworker.com/
GaryK
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9497 posts in 867 days
posted 833 days ago
Mike – I will show how I laid them out in a new forum or blog.
-- Gary, East TX -- The longest journey begins with a single step.
TonyWard
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284 posts in 1206 days
posted 833 days ago
GaryK
Your joints are great, just one question at this time ~ were you able to use any of them as part of this competition?
t.w.
-- Bandsaw Box Plans
GaryK
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9497 posts in 867 days
posted 833 days ago
TonyWard,
Yes, every one of them. I started out just building a box, but since I finished it with time to spare I
figured that I could use my extra time to fill it up.
-- Gary, East TX -- The longest journey begins with a single step.
Joel Tille
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214 posts in 1123 days
posted 832 days ago
Very Nice box GaryK. love the finish on that one.
Very good on your how to photos, and glad you disassebled the one sample. That was a little puzzling to look at.
-- Joel Tille
jockmike2
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7222 posts in 1125 days
posted 830 days ago
Nice job Gary, it looks like you got a lot out of this no glue joinery project. You sure impressed the heck out of me. Great job. I bet you learned a lot. jockmike
-- Mike. mwurm13@yahoo.com
Chuck Vosburgh
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26 posts in 876 days
posted 829 days ago
Thanks for your detailed descriptions and photos. Very educational and inspiring!
-- Chuck, chuckvosburgh.com
Joel Tille
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214 posts in 1123 days
posted 822 days ago
Gary – Congrats … have shown your box to a few friends. One of them had a question about where you get this wood. She searched the web for Sepele and found a couple of spots, but none of them had near the grain that you have. The store I go to does not carry this.
-- Joel Tille
GaryK
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9497 posts in 867 days
posted 822 days ago
It’s called either Pommele or Quilted Sapele, and it’s rare and expensive to find it with this much figure.
It goes for about $30 to $40 a BF.
I bought a big piece from http://www.anexotichardwood.com before I moved to Texas and
brought it with me.
You can see a sample on the top of the hope chest I made: http://lumberjocks.com/projects/1750
Hope this helps.
-- Gary, East TX -- The longest journey begins with a single step.
SPalm
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921 posts in 760 days
posted 645 days ago
Hey Gary, I just found this in the archives and had to comment. This is truly inspiring. I love joinery and you have kicked it up there. I love the explanation and visuals of what I have always called Japanese skarf joinery.
Thank you,
Steve
-- Stevethepeeve -- I'm no rocket surgeon
Russel
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2032 posts in 817 days
posted 644 days ago
Gary this is very impressive work. The engineering is well thought out and the final product is beautiful. I’m glad Steve kicked this back to the top or I might not have seen it.
-- When you give someone a chance it may well be their last.
Zuki
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1219 posts in 956 days
posted 644 days ago
i missed it also.
tks for sharing G.
-- The significant problems we face cannot be solved by the same level of thinking that created them
rikkor
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11338 posts in 753 days
posted 644 days ago
I am glad this got yanked out of the archives. Consistently good work, as usual.
Scott Bryan
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20068 posts in 700 days
posted 611 days ago
Gary,
Like rikkor I pulled this one too. (Actually I just needed to spend more time on the site). This is a gorgeous box. As always it looks like a wonderfully “engineered” project. You definately stepped outside the box on this one. By the way the carving adds nice detail to the piece. I am not sure that I would have had the “courage” to attempt something like this as an initial carving project. But this one is very nice. You should add more of this to your projects. It is really well done.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
jeanmarc
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1750 posts in 595 days
posted 456 days ago
very impressive work.Very Nice box GaryK.
-- jeanmarc manosque france
a1Jim
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15555 posts in 455 days
posted 264 days ago
Hey Gary
Once Again I’m very impressed and intrigued by your work. I really like the joinery in the box and the Box WOW but the blow by blow photos are no longer there. Were did you find all of those most unique joints you so beautifully executed ?
Jim
-- Jim from Heirloom Woodshop Southern Oregon
GaryK
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9497 posts in 867 days
posted 262 days ago
Thanks Jim. The pictures are still there.
If for some reason you can’t see them, you can find them here: http://www.arealnice.com/box/
-- Gary, East TX -- The longest journey begins with a single step.