|Project by Pat Cavanaugh||posted 09-06-2011 12:29 AM||22436 views||0 times favorited||8 comments|
A friend of mine was promoted to Chief Petty Officer and was required to attend a course as part of the promotion. Each of them must carry a “Charge Book” and the book must be protected in a box the promotee builds. Despite being a SeaBee, my friend doesn’t have the requisite woodworking skills to complete something this refined so he asked me to help.
He was given a pretty detailed list of parameters the box had to meet. These included seasoned hardwood, brass corners, handle, hasp and name plate, laser engraved USN Chief’s Anchor and Combat Warfare Badge, and blue velvet lining. He said he could handle the lining if I would help him out w/the woodworking. No problem!
I was able to find all the hardware locally with the exception of the brass corners. I had to order them from a company that specializes in kits for bulding cigar box guitars. And they were able to get them to me in 1 day from half way across the country. This was important as I only had three days to complete the box.
I resawed some red oak and planed it to 1/4” for the front and back of the box. I then took a 3/4” stick of red oak and ran a 1/4” rabbet along both edges. I them cut it to the necessary lengths for the box. After placing the front and back in, I wasn’t happy with the small gap around them. Since I knew the corners were going to be covered I decided to add a walnut strip to fill that gap. I routed an 1/8” groove right along the joint edge and glued in the walnut. I feel it adds a nice accent. Once the glue was dried I cut the sealed box in two with the back section slightly deeper than the front to ensure the handle was balanced. I then took the front to a trophy shop for the laser work. I applied 5 coats of spray polyurethane on the exterior and a couple coats of flat black spray paint to the interior (as a base for the velvet lining).
-- Pat - Biloxi, MS