|Project by Douglas Bordner||posted 07-27-2011 07:27 AM||2519 views||6 times favorited||27 comments|
I am still a smoker, but have chosen to stuff my own tubes to cut down costs. Having been throwing my daily rollings in a Tupperware tub for the last several years, I finally decided to build myself something to hold smokes at my desk (the traveling humidor will come later). I have been saving a slab of air dried Claro walnut burl for about a decade, waiting for the right project, and this is it.
The second project impetus was to use Veritas 5mm shelf pins
as a hinge. These are the economy type which don’t have a flat spade which fits under the shelf. These are just two 5mm rounds with a ≈7mm x 1mm flange between the two sides of the pin. The pin is captured in holes on the lid edge and blind holes in the box sides. I made the lift tab out of a small walnut – purpleheart – walnut lamination, shaping and cutting away to form a .125˝ x .325˝ tenon at the back of the knob. I made a tiny mortise (with a Japanese 3mm chisel – too nervy for router work) off center on the box to highlight a great grain area on the inside of the box, which draws the eye to the lift tab when the box is open. The cutaway at the front of the box was all done with hand tools. Let me take a minute to congratulate all you handcut dovetail woodworkers. I have a steep learning curve ahead before I will try the handcut dovetail as a joinery technique.
I added the homemade walnut-maple banding at the last. The plough is only about a sixteenth of an inch from the bottom of the box, which made for a slight pucker factor during the routing, but I hedged my bets by taping with shipping tape before the cuts to avoid torn out and blown out grain.
Finish is dewaxed garnet shellac (shellac.net) under Emtech EM 6000 waterborne lacquer from Target Coatings. Rubbed out to 2000 grit with Mirka Abralon pads. Interestingly enough. although developed for the automotive industry, these are now used in woodworking, and apparently for bowling balls too (not sure why, exactly).
Box is 8.5˝x 5˝x 2.75˝ with cherry and walnut sides (Thanks Dennis Zongker – I’m still working my way through your kind wood gift of offcuts), with a Spanish Cedar-Birch ply lamination bottom and Spanish Cedar lining. The box isn’t air-tight, as generally the smokes need a little drying after being rolled up, but I’m hoping the Spanish Cedar will add something to the bouquet.
-- "Bordnerizing" perfectly good lumber for over a decade.