Variation on a Theme

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Project by bibb posted 09-15-2011 04:43 AM 2079 views 39 times favorited 17 comments Add to Favorites Watch

Fellow LJ RJ showed us his great design for flip top pen boxes last year. Well his idea rattled around in the back of my head as other projects came and went. Recently my need for a business card box for my desk at work spawned the idea for these boxes. I asked RJ if he would mind if I incorporated his design into this variation and he graciously agreed to let me share these with you.
These are designed to fold up with the cards inside so you can throw them in a bag or pocket.
Rosewood and zebrawood. Each is appx. 4” x 3.25” x .75”
Thanks RJ

-- you may only live once, but if you do it right that's all you need

17 comments so far

View billculpepper's profile


66 posts in 2051 days

#1 posted 09-15-2011 04:49 AM

Oh yeah…this one goes in the favorites folder…

Very nice job!

-- Bill Culpepper, Indiana

View mmh's profile


3649 posts in 2809 days

#2 posted 09-15-2011 04:50 AM

These are beautiful! I think I need one . . . or two!

-- "They who dream by day are cognizant of many things which escape those who dream only by night." ~ Edgar Allan Poe

View Karson's profile


34994 posts in 3487 days

#3 posted 09-15-2011 05:31 AM

Beautiful. A fantastic job. I lov v v v v e the grain of the zebrawood.

-- I've been blessed with a father who liked to tinker in wood, and a wife who lets me tinker in wood. Southern Delaware soon moving to Virginia †

View Sandy's profile


153 posts in 3011 days

#4 posted 09-15-2011 06:00 AM

They’re beautiful. Do you have plans and a cutting/assembly sequence? Please blog the build with lots of explanation details, dimensions, and photos.

View patron's profile


13421 posts in 2428 days

#5 posted 09-15-2011 06:33 AM


and a build blog please

-- david - only thru kindness can this world be whole . If we don't succeed we run the risk of failure. Dan Quayle

View RogerBean's profile


1512 posts in 2040 days

#6 posted 09-15-2011 10:33 AM

Very, very nicely done. Design, wood selection, grain orientation, craftsmanship. These little guys have it all!

-- "Everybody makes mistakes. A craftsman always fixes them." (Monty Kennedy, "The Checkering and Carving of Gunstocks", 1952)

View Sandy's profile


153 posts in 3011 days

#7 posted 09-15-2011 11:15 AM

I thought about this project, as I could use some card and pen cases (See, RJ’s project), and I’m guessing that you need to start by determining the thickness of the case, which needs to be based upon the radius of the roundover router bit used to round the ends of the case when it’s assembled, i.e., for a .75 inch thick case you’d need to use a 3/8” roundover bit. I’m guessing that once you determine that thickness, you need a pair of pieces which will become the top/bottom which are then routed out to provide the hollow space which holds the cards (or RJ’s pens), bearing in mind that the top will ultimately have to be split along its length. That means that the routed out area will have to be longer on the top, by a kerf cut, than the bottom. I don’t think it’s necessary to trim the top/bottom to size until after they are routed for the content (cards or pen), bearing in mind that they will have to either start at, or be trimmed to, the same width. The top would then be split, with one piece being glued to the bottom, and the other piece being glued between the side pieces.

I think that for a given size case, I’d build a jig to accept a “blank” having the desired top/bottom width and a length equal to double the length of the bottom, plus two kerf cuts (1/8” each, one to separate the top from the bottom, and one to split the top). As I envision it the jig would have spacers to limit the movement along the fence of the router table whereby the top/bottom were hollowed out from a single blank at the same time. Following assembly, which might require some touch-up sanding to allow the parts to open/close smoothly, they could be drilled and hinged, followed by the end roundovers (both for thickness and the smaller roundovers around the ends, which could alternatively be sanded) on the router table. At least that’s how I’d attempt it, with additional adjustments based upon experience. If I get a chance before bibb or RJ explains how they really did it, I’ll give it a shot and try to document the procedure I use.

I had actually made a pen case along the same lines some time ago, but it opened differently.. This seems like an ideal project for a CNC router, or a Carvewright, and I’m also thinking that it might be done using my Festool MFS guides, rather than a router table, for the hollowing steps.

View HeirloomWoodworking's profile


237 posts in 2827 days

#8 posted 09-15-2011 01:36 PM

oh yeah! Nicely done my friend!

Something that I am deffinately going to add to my “must build someday” list. Like others have said above a blog would be great.

Thanks for sharing

-- Trevor Premer Head Termite and Servant to the Queen - Heirloom Woodworking

View Ken90712's profile


16034 posts in 2276 days

#9 posted 09-15-2011 02:01 PM

Well done looks great!

-- Ken, "Everyday above ground is a good day!"

View SPalm's profile


5185 posts in 2969 days

#10 posted 09-15-2011 02:04 PM

Very nice.
I gotta make some of those.


-- -- I'm no rocket surgeon

View Douglas Bordner's profile

Douglas Bordner

3995 posts in 3151 days

#11 posted 09-15-2011 02:40 PM


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

View newTim's profile


562 posts in 2694 days

#12 posted 09-15-2011 06:03 PM

Makes me want to take a card.

-- tim hill

View BarbS's profile


2434 posts in 3172 days

#13 posted 09-15-2011 07:49 PM

Perfect! Thanks for sharing those.


View Randy63's profile


240 posts in 1979 days

#14 posted 09-16-2011 01:36 AM

These are terrific. I could think of several people these would be nice for. Thanks for sharing.

-- Randy, Oakdale, Ca.

View Roper's profile


1367 posts in 2800 days

#15 posted 09-25-2011 01:53 PM

I love these Bibbs,I may need to get one from you.

-- Roper - Master of sawdust-

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