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I must say when Martin first posted this challenge I thought he was a little crazy! Just how and the heck can you build much of anything without glue and fasteners?
Humm well at first I really had no intention on entering anything as I had really no idea what I could build if anything at all. However for weeks I just couldn't let the thought go and well I am happy to say oddly enough thank god for traffic?? Some people talk on the phone or text their friends but this wood geek designs his LJ challenge. No I was drafting while driving but I did run over numerous ways to build just about anything with out glue or fasteners and if I had more time I surely would have but… without further rambling here's my creation.
Constructed mainly from scraps around the garage Cocobolo (hinges), Kingwood (feet), Walnut (pins) Soft Maple (sides) and curly maple for the top this small box measures 6"W x 5"H x 9"L. The sides are ½" in thickness where as the top and bottom are 3/8". The sides utilize through dovetails to ensure the book matched, sliding dovetailed top stays tight where as the bottom is one solid piece. The feet use what I believe you call a fox tenon?? and are made of Kingwood turned from a pen blank. I must say that my extent of thoughts on grain direction have been primarily for esthetic reasons but it became clear that not thinking now would turn my wedge into a log splitterL I needed to be sure my cuts and wedges stayed perpendicular to each other or else! Anyways, once the bottom was assembled I could now move on to assembling the box as it would be tough to clean up the tenons inside the boxL I assembled the box using clamps to ensure the best fit possible and then while clamped I drill and inserted the walnut pins. I trimmed and cleaned up the remaining pins, finish sanded the entire box and moved on to the band saw where I separated the top from the bottom. My next step was to cut dados for the hinges and then machine the Cocobolo to fit the dados. At this point I used some 1/8" dowel to secure the hinges and 3/16" dowel to use as a hinge for the top. Next I used a "T" slot cutter in my router to make room for the 3/16" dowel and rounded the back and bottom with a 3/8 radius bit to allow the top to open, whewww almost done…Now the only step left was to create some sort of handle but unfortunately I still needed to get started on the finish and well I was running out of time so after a couple minutes of thinking?? I came up with using a cove bit to create a small recess.

Are we finished yet??
Thank god something easy! Lighted sanded with 220 then wiped on 4 coats of Arm-R-Seal to help bring out the curl in the top.

On a side note, while test fitting I actually fractured a portion of the right side and wanted so bad to glue it but… what the heck I stabbed an additional walnut pin in there and viola!

I must say this has been one of the most rewarding and eye opening projects I have taking on in a very long time and look forward to the next!

Thanks,
Ron

BTW for anyone that's interested I hope to have the plans completed in the next couple of daysJ

Gallery

Comments

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Here's the process
Getting started with the bottom

Adding the wedges to the tenons

Sliding dovetail for book matched top

All the pieces ready for assembly. I had to plunge the ploughs and dados so they wouldn't show through

Almost ready to pin

I added the clamps so I could sure the joints stayed tight while I added the pins

Pins added

Ready to separate the top from the bottom

Pinning the bottom of the hinges

Oops I actually cracked this area when I mocked it up the first time, oh well nothing another pin didn't fix:)

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Wow
Very nice work Ron
I love how you did the corners and them hinges are slick.
Beautiful job.
 

· In Loving Memory
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Very elegant box. Crisp and clean.
 

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Thanks guys, I really would to have loved to done more but I got busy with other stuff so… this was nonetheless fun and of course I learned a bunch:)
 

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Very impressive. Good luck.
 

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Ron, this is a beautiful box and you know what I say about small wooden boxes, I just love them! I particularly like the feet and hinges. Very original.

Thanks for the extra photo's - they make your project very easy to follow.

Best wishes.
 

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Ron,

I'm impressed! Well done.

Whit
 

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Ron, excellent workmanship. Nice presentation. Thanks for sharing with us.
 

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Wow! What a finish! I like how you turned your mistake into a beatiful addition for a unique look!
I am looking forward to the plans!

Your simple elegance is superb!

God Bless,
Hawg
 

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Ron;

BEAUTIFUL work. Very creative and very crisp execution of the joinery.

Lee
 

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Great looking box and the pictures of the process was nicely done. The judges have their work cut out for them and a tough job it is going to be.
 

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Ron,
Very beautiful, elegant, and yet complex box. Isn't it amazing how complicated even a small box can be? Your pictures and explanation are very instructive for many of us. Thanks a lot!
 

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Beautiful Box…you did an outstanding job. very good jointery and you made a wonderfull recovery when faced with a problem like a cracked board.

Don, I am now becoming more like you….I like these boxes…I think I may have to give up my "Table Thing"

Great work and God Bless.

Greg
 

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Thanks so much for all the kind words:) Based on all your comments it appears that it may have been actually a good thing I didn't have more time as I probably would have needlessly added things that weren't needed. I guess this is a "less is more" situation? Thanks again guys for all the support:)
 

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Great box, Ron! I really appreciate you taking the time to document the process! Really nice! I need to try and make a box!
 

· In Loving Memory
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Very ingenious and put together tight. Impressive. jockmike
 

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Thanks again guys, I should have the plans completed in hopefully by the end of the week so… I think I may have to get on the box band wagon with Don and Greg this was fun! Mike this box is so tight that I bet if I took it out of the desert to say… the east coast it would probably explode, LOL I will really be curious as to how it holds up?
 

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SWEET

again, I have to say that this joinery challenge has been a rough journey but "I must say this has been one of the most rewarding and eye opening projects I have taking on in a very long time and look forward to the next!" makes it all worth while.

I'm glad that people voted this into the top two categories!
 

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The only problem now is how do you top this challange??? I too can't wait for the next!!!
 

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Well; I'm impressed. The pins are very cool and the hinge idea is … very cool too. Nice clean look.
 
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