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Single 2x4 and Not Just Any Box Entry

Project by Rich_S posted 214 days ago 5970 views 4 times favorited 47 comments Add to Favorites
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Rich_S

54 posts in 308 days


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Single 2x4 and Not Just Any Box Entry Single 2x4 and Not Just Any Box Entry Single 2x4 and Not Just Any Box Entry Click the pictures to enlarge them

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


47 comments so far

View gizmodyne's profile

gizmodyne

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

View Jojo's profile

Jojo

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/

View GaryK's profile

GaryK

8404 posts in 431 days


posted 214 days ago

Pretty cool! Nice design.

-- Gary, East TX -- The longest journey begins with a single step.

View YorkshireStewart's profile

YorkshireStewart

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.

View rikkor's profile

rikkor

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

View Sawdust2's profile

Sawdust2

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.

View Russel's profile

Russel

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.

View shaun's profile

shaun

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!

View Les Hastings's profile (online now)

Les Hastings

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!)

View MsDebbieP's profile

MsDebbieP

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)

View Scott Bryan's profile (online now)

Scott Bryan

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.

View Critterman's profile

Critterman

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

View Thos. Angle's profile

Thos. Angle

3243 posts in 405 days


posted 214 days ago

Outstanding! Excellent design and resourcefulness. this should be a winner.

-- Thos. Angle, Owyhee Design, Oregon

View SPalm's profile

SPalm

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

View Popintraining's profile

Popintraining

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

View DAN's profile

DAN

2845 posts in 425 days


posted 214 days ago

this is about as nice as it gets

-- ..... art for lifes sake

View Andy's profile

Andy

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

View CharlieM1958's profile

CharlieM1958

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"

View Paul's profile

Paul

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

View Rich_S's profile

Rich_S

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

View mot's profile

mot

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)

View Bob Babcock's profile

Bob Babcock

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

View Dominic Vanacora's profile

Dominic Vanacora

376 posts in 312 days


posted 214 days ago

You have made mother nature proud.

-- Dominic, Trinity, Florida

View Tim Dorcas's profile

Tim Dorcas

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

View rjack's profile

rjack

110 posts in 298 days


posted 214 days ago

I can’t believe it was with a 2×4. Very nice!

-- Roger - Havertown, Pennsylvania

View Tomcat1066's profile

Tomcat1066

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!

View Douglas Bordner's profile

Douglas Bordner

2447 posts in 506 days


posted 214 days ago

Great work and very artistic. Lookin’ good.

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

View Dick Cain's profile (online now)

Dick Cain

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

View MsDebbieP's profile

MsDebbieP

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)

View Kerry's profile

Kerry

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

View relic's profile

relic

315 posts in 379 days


posted 214 days ago

Absolutely fantastic. Wow

-- Andy Stark

View Blake's profile

Blake

1874 posts in 317 days


posted 214 days ago

That is INCREDIBLE!!!

-- Dust collectors suck.

View Greg3G's profile

Greg3G

625 posts in 528 days


posted 214 days ago

Excellent work, great design, outstanding finish.

-- Greg - Charles Town, WV

View mrtrim's profile

mrtrim

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

View molarman's profile

molarman

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

View Karson's profile

Karson

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

View scottb's profile

scottb

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

View Don's profile

Don

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/

View dustynewt's profile

dustynewt

323 posts in 305 days


posted 213 days ago

Beautiful and graceful design. Great box.

-- http://dustynewt.webs.com/

View Hawgnutz's profile

Hawgnutz

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

View FlWoodRat's profile

FlWoodRat

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

View furnitologist's profile

furnitologist

166 posts in 456 days


posted 212 days ago

Hey Rich…..........pretty interesting design. Are you thinking to work the design further, larger scale???

View Rich_S's profile

Rich_S

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

View TopE5's profile (online now)

TopE5

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.

View woodup's profile

woodup

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!"

View yippee's profile

yippee

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 ... :)

View MsDebbieP's profile

MsDebbieP

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)

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