|Project by Tim||posted 12-20-2010 06:09 AM||1234 views||0 times favorited||11 comments|
Whew! What a learning curve. The project was modelled off of a video series done by FWW. I made it as a thank you to a friend who helped me land a new job. Therefore, I made sure it was big enough for a bottle of booze, which wasn’t as easy as I thought as it got smaller and smaller each time I messed up the miters!
It is made of bird’s-eye maple sides with walnut top, bottom and splines. Finish is 2 coats of de-waxed shellac with a couple drops of trans tint. Then 2 coats of poly.
What did I learn? Everything! Re-sawed on the table saw. Miters were done with a large V router bit. Splines on the table saw what a shop-made jig. Where did I mess up? Everywhere! The resaw went surprisingly well. I have an older contractor style 10” craftsman and I didn’t think I’d have the juice. A little raise of the blade on each pass and I had zero saw-blade burning. A big Freud rip blade helped. I was psyched. I then used a couple of sticks as spacers and clamped the boards to let them acclimate as flat as possible. Then, took them out of the clamps and life got in the way. About 5 weeks passed and one board cupped a little on me. Eventually got it together, leading to big learning #2. I borrowed a neighbor’s brand new L-N #4 to help with the BE maple. it was awesome, but tore out the splines. Oops. #3: mortised for hinges that I found to be the wrong kind afterwards. Correct hinges were smaller (of course!). And then there was #4: the finish. The shellac pooled along the bottom and top edges of the lid which made it really uneven. I propped the lid up on painter’s triangles but I have to learn how to handle shellac better. I need to do some practicing but I will never use a foam brush again for finishes of any kind. So far, the foam brush is the only place I feel Norm A has led me astray.
Thanks for reading. Any suggestions on finishing boxes in their many parts and materials would be greatly appreciated.