| Project by Rich_S | posted 214 days ago | 5970 views | 4 times favorited | 47 comments | ![]() |
This is my entry for the single, multi-purposed 2×4 contest. This box is constructed from one construction grade 2×4x8’ SPF (Southern Pine Fir) that was on sale for $1.97 at our local big box lumber yard. There were several funny things about the 2×4. First, it wasn’t straight. It had about a 1” gradual bow over its entire length and had been passed up many times as others had picked through the lumber pile. Despite the bow it was nearly perfect. It only had one little knot, which was soild and tight, plus it was this creamy white color, not the typical yellow hue. I took it home and started on the plans. I had this concept in mind for a while, but for a much larger piece of furniture so I had to scale the idea way down. Once I had figured the overall shape/size, I then worked out a cutting diagram for the 2×4 to see if I could really get all the parts. It turned out short, so I had to scale my concept down even further. I ended up rescaling the whole idea once again when I found out my 2×4 which should have been 1-1/2” x 3-1/2” was really 1/8” less than that in each dimension. Once I knew I could make it work then I started cutting/resawing/planing/sanding to get the basic parts. The legs are a tapered bent lamination consisting of 4 layers that taper from just strong of 3/16 to 1/8” over thier length. I accomplished the taper by using my 16” disc sander and a fence I constructed. I made two bending/clamping forms from MDF and lined them with cork. I used plastic resin glue to adhere the lamination layers. The sides of the case are glued up panels that were resawn and bookmatched and are approx 3/8” thick. The back panel is bookmatched also, but is only approx 3/16” thick. The base and top are roughly 3/8” thick. and were glued up bookmatches as well. The door rails and stiles are 1” wide and just under 1/2” thick. The door panel is just strong of 1/8” thick and was bookmatched as well and is captured into the door rails/stiles by a 1/8” wide by 3/8” deep dado. The flairs on the top were shaped using a small panel raising bit in a router table. The flairs and the main part of the top were joined with a 1/8” spline, 1/4” wide cut from some thin strips left over during resawing. The sides of the flairs taper at 20+ degrees to continue the flow of the legs. The strecthers between the legs are 3/8” thick and roughly 1/2” wide. The legs and the door panel were colored using a combination of blonde shellac tinted with TransTint Bordeaux color. I wanted to mimic the deep red color of Bloodwood. The entire case was then sprayed with several coats of Watco gloss laquer. All that was left over from the 2×4 is a single little 1”x1” square about 1/16” thick along with a bunch of planer shavings and sawdust. I ended up working in millimeters most of the project due to the size and thickness of the joints. The overall size of the box is 17-3/4” tall by 15” wide x 8” deep. This was a fun project that really kept me on my toes since there was no room to make a mistake or make test pieces to cut.
-- Rich, Madison WI
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47 comments so far
gizmodyne
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1476 posts in 532 days
posted 214 days ago
Great design. Great work.
-- -John "Do I have to keep typing a smiley? Just assume it's a joke." www.flickr.com/photos/gizmodyne
Jojo
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319 posts in 415 days
posted 214 days ago
Wow! Amazing what you saw inside a humble 2×4. Great luck on both of the contests… because you are entering it in both, aren’t you?
-- Jojo, shopless in Kyoto · http://www.japanese-woodworking-tools.com/
GaryK
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8404 posts in 431 days
posted 214 days ago
Pretty cool! Nice design.
-- Gary, East TX -- The longest journey begins with a single step.
YorkshireStewart
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624 posts in 344 days
posted 214 days ago
Amazing that this came from the 2×4 Rich. A marvellous achievement in what’s turning out to be a really great competition.
-- Res severa verum gaudium - True pleasure is a serious business.
rikkor
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7112 posts in 317 days
posted 214 days ago
Fantastic! When this is over I hope someone puts together a slide show of all the projects. I think it would be jaw-dropping.
-- Maplewood, MN
Sawdust2
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827 posts in 530 days
posted 214 days ago
Not only was it construction grade 2×4 it was everyone else’s reject!
This comes close to making a silk purse out of a sow’s ear.
-- No piece is cut too short. It was meant for a smaller project.
Russel
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1214 posts in 382 days
posted 214 days ago
A very impressive piece of work. It’s beautiful the size it is and I can imagine how impressive it would be at full scale. Very cool.
-- When you give someone a chance it may well be their last.
shaun
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360 posts in 348 days
posted 214 days ago
and the bar gets raised again. Nice work Rich!
-- I've cut that board three times and it's still too short!
Les Hastings
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407 posts in 216 days
posted 214 days ago
Boy who needs exotic lumber anymore, lets all just use 2×4’S, Great work and design,,,,,EXCELLANT!!!
-- Les, Wichita, Ks. (I'd rather be covered in saw dust!)
MsDebbieP
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11555 posts in 603 days
posted 214 days ago
unbelievable.
I’m picturing the misfit 2×4 waiting and waiting and waiting to be selected and taken home to be made into something. I see its sad reaction as it is tossed aside, over and over and over again.. And then the pride it felt when it was finally chosen and taken home. I can hear it saying “I am going to give 120% to this project. I’m going to be the best 2×4 there ever was.” You have done it proud!! Stunning.
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
Scott Bryan
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8493 posts in 264 days
posted 214 days ago
The design of the box is just great and the staining/finishing work is stunning. As I have said with each of these projects- I will never look at a 2×4 in the same light again.
Kudos for the posting. This is really a beautiful project.
-- With God's help all things are possible- even woodworking. Woodworking is not just a hobby, it is an (expletive deleted) expensive hobby.
Critterman
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452 posts in 253 days
posted 214 days ago
You saved it! That little misfit 2X4 so sad in the pile of better lumber at the big box store. You brought it home and gave is a beautiful new life as a stunning new box that all the other 2X4’s envied. “Sniff” What a wonderful story. “LMAO” Seriously a fantastic design and you have great insight to see a use for an old bent 2X4 like that, not to mention the planning and great execution. Great entry.
-- Jim Hallada, Chesterfield, VA
Thos. Angle
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3243 posts in 405 days
posted 214 days ago
Outstanding! Excellent design and resourcefulness. this should be a winner.
-- Thos. Angle, Owyhee Design, Oregon
SPalm
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702 posts in 325 days
posted 214 days ago
WOW!
Truly a fantastic job.
I am humbled by your craftsmanship and the finish is extraordinaire.
-- Stevethepeeve -- I'm no rocket surgeon
Popintraining
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109 posts in 280 days
posted 214 days ago
Unbelievable, that’s just beautiful
-- Illegitimis nil carborundum - Don't let the bastards grind you down http://woodworkingtipsfrompop.com
DAN
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2845 posts in 425 days
posted 214 days ago
this is about as nice as it gets
-- ..... art for lifes sake
Andy
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296 posts in 351 days
posted 214 days ago
This piece conveys a sense of movement…..of life.Very good use of contrasting colors and lines.This is the result of a lot of planning and a very creative mind.Well done Rich.
This shows what is hiding in our wall studs, begging to get out.
-- " Stubborn tenacity substitutes for natural ability" ANDY
CharlieM1958
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3965 posts in 661 days
posted 214 days ago
I’ll be darned if I can figure out where some of you guys are finding so much wood in a 2×4!
-- Charlie M. "Woodworking - patience = firewood"
Paul
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589 posts in 535 days
posted 214 days ago
Gosh, that’s wonderful!
I thought it would be unlikely that one project could win both categories until now.
-- Paul, Texas
Rich_S
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54 posts in 308 days
posted 214 days ago
I was very surprised too in the end at how much wood can be in a 2×4! It gave me a whole new appreciation for how much wood I’ve probably wasted in all the other projects I’ve built. The whole key was thin kerfs. Lots of bandsaw work to resaw and rip pieces to width followed by extremely light passes on the jointer and planer (1mm or less) to joint and face pieces. Crosscutting and making the little tennons on the end of the door rails was done on my crosscut sled on the table saw. I got really lucky with this 2×4 in that 1) the store kept all their lumber inside a heated building so it was dry and didn’t move all over the place after I cut it and 2) a lot of its grain ran perpendicular to the faces. When I was staring at the pile of lumber at the store this piece was laying on the top front of the bunk with a bunch of other pieces that had pitch pockets, some wane and bark on the edges, etc. Initially I passed it up as I started to dig through the pile but came back to it because it looked pretty good despite the bow.
-- Rich, Madison WI
mot
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4837 posts in 479 days
posted 214 days ago
That’s awesome, Rich! Just awesome!
-- You can discover more about a person in an hour of play than in a year of conversation. (Plato)
Bob Babcock
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1811 posts in 529 days
posted 214 days ago
Wow…what a great piece. I love the top floating above the legs. Great design and execution. A definite top contender for both categories.
-- Bob, Carver Massachusetts, Sawdust Maker http://www.capecodbaychallenge.org
Dominic Vanacora
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376 posts in 312 days
posted 214 days ago
You have made mother nature proud.
-- Dominic, Trinity, Florida
Tim Dorcas
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40 posts in 301 days
posted 214 days ago
Rich,
I am incredibly impressed with your design and execution. That you made it with a 2X4 only speaks to your craftsmanship. I also appreciate you describing your process. Can’t wait to see what you make next!
-- www.responsetolight.com - A Woodworking & Renovation Blog
rjack
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110 posts in 298 days
posted 214 days ago
I can’t believe it was with a 2×4. Very nice!
-- Roger - Havertown, Pennsylvania
Tomcat1066
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556 posts in 239 days
posted 214 days ago
Wow! Very nice design and a great job with less than ideal wood!
-- "Give me your poor tools, your tired steel, your huddled masses of rust." Yep, I ripped off the Statue of Liberty. That's how I roll!
Douglas Bordner
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2447 posts in 506 days
posted 214 days ago
Great work and very artistic. Lookin’ good.
-- "Bordnerizing" perfectly good lumber for over a decade.
Dick Cain
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4809 posts in 742 days
posted 214 days ago
Beautiful, unique, & superb craftsmanship!
Someone finally invented the ’‘Board Stretcher’’, you better get a patent. LOL
-- Dick Cain, Hibbing, MN. http://www.woodcarvingillustrated.com/gallery/member.php?uid=3627&protype=1
MsDebbieP
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11555 posts in 603 days
posted 214 days ago
critterman: I think I see a movie in this!
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)
Kerry
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96 posts in 233 days
posted 214 days ago
That’s excellent! I really like the form of that piece. The fact that it’s a 2×4 is secondary to the great design.
Kerry
-- Alberta, Canada
relic
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315 posts in 379 days
posted 214 days ago
Absolutely fantastic. Wow
-- Andy Stark
Blake
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1874 posts in 317 days
posted 214 days ago
That is INCREDIBLE!!!
-- Dust collectors suck.
Greg3G
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625 posts in 528 days
posted 214 days ago
Excellent work, great design, outstanding finish.
-- Greg - Charles Town, WV
mrtrim
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1511 posts in 323 days
posted 214 days ago
exellent design work ! awsome piece ! i hope all you guys in this 2×4 contest are pleased , now i dont even feel competant enuff to work with frameing lumber ! gee whizz
-- if you aint the lead dog the scenery never changes
molarman
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27 posts in 261 days
posted 214 days ago
Great lines!! This is a piece of art!
-- Woodworking is not a destination....it's a joinery !!! http://smilesrus.com/pages/woodgallery.html
Karson
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12617 posts in 843 days
posted 214 days ago
And Art du jour. A fantastic inventive piece. Great job.
-- Karson Southern Delaware karson_morrison@bigfoot.com
scottb
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2855 posts in 770 days
posted 214 days ago
Not only is that a beautiful new life you’ve given that 2×4, The box is a fairly impressive size to have come from one – a small, rejected one.
Great design, I can easily imagine it in a lirger scale in nicer wood – but I think we’ve been learning that we don’t need to hit the exotics anymore!
-- I am always doing what I cannot do yet, in order to learn how to do it. - Vincent Van Gogh
Don
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2586 posts in 619 days
posted 213 days ago
Oh no – how am I going to judge this comp?
This is just fantastic!
-- CanuckDon "I just love small wooden boxes!" http://www.canterburybaptist.org/
dustynewt
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323 posts in 305 days
posted 213 days ago
Beautiful and graceful design. Great box.
-- http://dustynewt.webs.com/
Hawgnutz
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483 posts in 519 days
posted 213 days ago
Fantastic execution with the humble, rejected 2X4! The ugly duckiling of woodorking!
This has my vote, fer sure!
God Bless,
Hawg
-- Saving barnwood from the scrapyards
FlWoodRat
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237 posts in 352 days
posted 212 days ago
I am humbled by you abilities to not only envisiion the end project, but to so expertly craft the item. Well done
-- Even the best of men relish a little spice every now and then... HG Somers, circa 1905
furnitologist
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166 posts in 456 days
posted 212 days ago
Hey Rich…..........pretty interesting design. Are you thinking to work the design further, larger scale???
Rich_S
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54 posts in 308 days
posted 210 days ago
Yes, I am pretty certain I’m going to do a larger scale of this project as a nightstand for a scholarship competition, but it will be much more dramatic in terms of the overall design of the legs and top for certain as well as the casework…..probably more toward the shapes of an Asian temple or something. This work was used as a test of some construction concepts for stability and strength of the space frame style legs and as a challenge to myself to see if I really could make this out of a 2×4. I like the work you did, furnitologist, on the Carlo Mollino style coffee table….very inspiring….I picked up a copy of the book you referenced after watching your videos on the construction of your version….great videos and keep up the work!
-- Rich, Madison WI
TopE5
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277 posts in 382 days
posted 203 days ago
You have a an astounding mind for beauty, and art…....I could never see something this beautiful in a stud that I use everyday to build walls with.
woodup
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105 posts in 386 days
posted 203 days ago
Congrats on a great placement in both categories with this project! I really love the lines/curves and the stains really make it pop visually. The 2×4 factor really captures the imagination! Way to go! Michael
-- Michael, Fort Worth, TX. "I wood if I could!"
yippee
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9 posts in 161 days
posted 160 days ago
Wow – what creativeness – taking a new look at my “strange wood” stockpile in the barn …
-- Currently-from-Grand-Rapids-but-looking-to-move-to-beautiful-Traverse-City ... :)
MsDebbieP
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11555 posts in 603 days
posted 160 days ago
I’m glad this came up again … VERY impressive work.
-- "Functional WoodArt" by Debbie, Canada (http://www.execulink.com/~yohan)