Rachels Box

Andy,

This is another winner! You’ve definitely got the hang of making boxes ;^D

-- Tom, Surfside Beach, SC - Romans 8:28

nice boxes you’ve been makeing. did you say you use a side grinder?

-- bryano

That finish is truly artistic! It makes the wood seem almost liquid. I’m impressed is an understatement.

-- Robb

OK, OK, give me a break from this eye candy! Wow! I’m not sure my heart can take much more. I’ve never thought of the fact that I just love small wooden boxes as a fetish – but I am beginning to wonder. LOL

This is terrific – fluid – molten – alive!

-- CanuckDon "I just love small wooden boxes!" http://www.canterburybaptist.org/

Looks like you were thinking outside the box! Incredible artistry. What did you use to finish the box?

-- Hard work spotlights the character of people; some turn up their sleeves, some turn up their noses, and some don't turn up at all!

Andy your boxes are at a whole new level – up there with Don’s and very few others. I really like the “forming” and wood selection. I’ve read in another post that you use Deft lacquer for these boxes. Would you please take a minute and be a little more specific on the finishing technique?

-- Bill - "Suit yourself and let the rest be pleased." http://www.cajunpen.com/

It almost looks like the box melted. Just wonderful.

-- Thos. Angle, Owyhee Design, Oregon

Wow! I was down in the shop making a box. I think I might toss it in the burn pile. These are great. I’m going to take up cross stitch.

-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)

Ah come on Mot – just because Andy is a Michelangelo of boxes there’s still time to become a Cellini of boxes. I certainly won’t give up. He just inspires me to try harder.

Andy, you are one of a kind. Most excellent. This series of boxes are inspired and inspiring.

-- "Bordnerizing" perfectly good lumber for over a decade.

Wow that is a beautiful box!

-- Krisztian (from Hungary) VA

pretty box … you took flat sawn maple and turned it into a exotic … great project

-- ..... art for lifes sake

Extraordinary…amazing look!

-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org

Congrats Andy, you almost made our mate Don faint with your flowing box!

It’s a truly exceptional box that of yours. It clearly reminds me of the melting clocks of some of most famous Dali’s paints. Please, tell us more about the actual process of shaping the lid.

-- Jojo, shopless in Kyoto · http://www.japanese-woodworking-tools.com/

first: awwwwwwwwwwwwwww you made it for your daughter because you love her a lot!!!

the box is beautiful.. it almost looks like a cloth box, as its shape “distorts” with dips and dives.
I can’t wait to see the video of you carving the shape of a box (hint hint)

-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)

Wow, there is nothing I can say that would do justice to that box. Andy, the box itself is a special occasion.

-- I've cut that board three times and it's still too short!

I just want to pick it up and feel it, tough it, hold it maybe buy it a drink :)

-- "so much to learn and so little time"..

I think everyone else has pretty much said it, but man – that is real talent. I’d love to hear and see more about how you make these boxes.

-- John

totally gorgeous – nice organic shape, yeah – “melty” looking

-- I am always doing what I cannot do yet, in order to learn how to do it. - Vincent Van Gogh -- http://snbcreative.wordpress.com/

Wait, hold on – no putty allowed? Are you sure you’re not sculpting these out of some quality Wood grain looking Play-Doh?

-- I am always doing what I cannot do yet, in order to learn how to do it. - Vincent Van Gogh -- http://snbcreative.wordpress.com/

Enough already!...any more praise and my head wont fit through the shop door! Thank you all very much for your kind words.
I will do my best to answer your questions,but be sure and read my previous posts,I may have already touched on it earlier.
This is not a complete step by step how to on building this box.Just an overview.I do intend on doing a complete box in the future,but many photos will be required to make it clear.I dont presently have time to do it.I hope the following helps some of you get started.
Shaping: Note: I recommend starting off your first box with just shaping the top and softening the corners,less risky.
I mount the box to the corner of my bench, down through the bottom using 2 screws.This lets me shape the top and sides,and when I need to do the back, I remove one screw and pivot it around backwards on the other, and then reinstall the first one. This keeps the box from even wiggling.The holes are very small if you use sheetrock screws and dont predrill.The velvet pad hides them from the inside and a little filler takes care of the bottom. A piece of veneer is an option if the plugged holes show too much. At this point I have already glued the medallion into the lid and it stands proud by about 3/8”.The lid is still just a blank and fits into the rabbeted body very tightly,and it stands proud of the body by 3/8”.I drill the 1/8”pin holes and put roofing nails in to keep it in alignment,so nothing can shift,and this keeps me from accidently grinding away too much material from the hinges seat.The roofing nails are a perfect fit and the big heads are easy to grip for removal.The pins are 1/8” brass brazing rod,a few $$ for 3’ft.
Also,the splines have been put in and sanded smooth,then all four sides have been tapered about 5 degrees on the bandsaw.
So then I take my Makita 4” angle grinder,the kind used for grinding metal,and put on a #80-100-150 grit disc with the flexible rubber backer.DO NOT attempt to use regular sanding discs for wood! They can come flying off and can cause serious injury.Now this thing will eat wood in a hurry! Grit will depend on the hardness of the wood.
I start rounding over the medallion to meet the top and then the top until it just meets up with the edges of the sides.I stop often and take stock.Dont get in a hurry or you will go too far.Keep in mind that after the rough shaping,there is still sanding to blend everything into a smooth flow,which will remove even more wood.This box is dependant on very close tolerances.You can wind up with thin/brittle box edges if your not careful.
After getting the top formed,I radius the corners and then start contouring the sides.Visualize the finished look as you are shaping.Learn to read the grain as it is being exposed.One valley should smoothly roll over a hill and down into another,like a landscape.The entire box should have an organic,natural flow about it.If it doesnt feel right….. then it wont look right.Go slow and trust your feelings.
For a more elegant look,like the Walnut box, you may want to skip this part.But the deep valleys are a great way to make simple straight grained lumber, such as this Maple and Bloodwood, come alive.
After all the rough shaping has been done,then the lid is removed and its edges are shaped, very slowly and carefully, to allow it to pivot.The bottom edge of the lid needs to be radiused so it will clear the box sides.But try a little at a time,using the nails to test the pivoting,over and over and over.Go slow.You want the lid to barely clear the sides as it opens.Too much and your gap will be uneven and/or too large.
Finishing:
When the lid works smoothly,cut the brass pins to set just below the surface of the sides and plug the holes with matching wood.Then finish sand the entire box.I usually only go to about #220,except on some woods like Myrtlewood,which require up to #320 to give it that depth. I spray the box and lid seperately.I start with a fairly heavy coat and let that dry about an hour.I use this as a sealer coat.I sand most of it off and this exposes any scratches I may have missed in my sanding.I work on these and then recoat and check again.Its the best way for me to see flaws. I sand with #320 between coats,and wipe with a clean t-shirt.No tack cloth needed. I give it at least four coats,depending on the wood and how I like the results. Just make sure to spray it on as heavy as you can without it running. Keep it wet,but only one coat at a time and let it dry about an hour between coats.This of course depends on temp and most of al onl humidity. I hold the box up to the light and view it from every angle looking for flaws and redo as needed.After it has dried for several hours,I take clean copy paper,soften it up by wadding it into a ball,then flatten it back out,and buff the surface with it.This knocks off the nibs you often get in lacquer.FYI: I prefer Deft lacquer because it has a better spray head than most,flows smoothly and I get consistant results.I have used most every brand on the market and keep coming back to it.I dont recommend the clear spray paints.They dont rebond to previous coats like lacquers do.

_

-- " Stubborn tenacity substitutes for natural ability" ANDY

Okay, since you don’t want any more praise….

These boxes really suck, Andy. Ship them to me and I’ll see if I can “fix” them.

lol!

-- Charlie M. "Woodworking - patience = firewood"

Charlie. I will send a batch as soon as I whip them up. I’m glad you like them, thanks.

-- " Stubborn tenacity substitutes for natural ability" ANDY

thank you for taking the time to explain the process!

-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)

Thanks for the explanation. Now, when is the video coming out? ;-)

-- John

Great explanation and writeup. I look forward to trying this out in the shop this winter…

-- Hard work spotlights the character of people; some turn up their sleeves, some turn up their noses, and some don't turn up at all!

Amazing, amazing. Adding you to bud list and this to my favorites.

-- Check out my new website! http://www.theeasellife.com

Andy, I made here to Lumberjocks. Thanks for the info…John (dustnlint at flickr)

-- Odie, Confucius say, "He who laughs at one's self is BUTT of joke".

A truly great box that will hold its own in the competition.

-- Res severa verum gaudium - True pleasure is a serious business.

I am glad this came out of the archives so I got to see it. “Wow” is about all I can say!

-- Maplewood, MN

ditto

-- The significant problems we face cannot be solved by the same level of thinking that created them

Very nice…the flowing kinda bent shape reminds me of the ceramic coffee cups I used to see at souvenir shops in the Badlands of the Dakotas where the artist had lightly squeezed the sides of the cup before firing…I remember the saying on these cups as “I got smashed in the Badlands of South Dakota”.

-- Rich, Madison WI

The “pillowed” look of this thing is really amazing! Great concept, proportions and finish! AWESOME!
Oh, that’s right you don’t want praise….so I take it back…...not!

-- Carl Rast, Pelion, SC

ABSOLUTELY AMAZING!!!!!

Let me add another GORGEOUS to the list Andy. It is awesome to see this type of artistry and talent. Seeing work like this is a real awakening.

Thanks for making my day.

-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.

Andy;

What a great design. So fluid and graceful.

You should be quite proud of it!

Lee

-- by Lee A. Jesberger http://www.prowoodworkingtips.com http://www.ezee-feed.com

Thank you for the compliments and for all the votes that helped this box place 3rd.

-- " Stubborn tenacity substitutes for natural ability" ANDY

This has to be my favorite wooden box of all time! Just GREAT!

-- miles125, Alabama.."Architecture is frozen music""

Sweet project. I have daughters too that I love to build for- just because. Nice job!

-- A thing of beauty is a joy forever... - Keats

Andy, I just recently became a LJ member and came across this in looking at the “most favorited” postings. I love this box! The contrast between the bloodwood and maple is great. You do some incredible work!

-- Martin, Kansas

Absolutly beautiful….......thanks for posting this….....just found it

-- I'm not slowing down,everythings just going by faster!

Thank you Miles,Jm,Martin and John.

-- " Stubborn tenacity substitutes for natural ability" ANDY