mahogany helmet case with carving and glass etchings

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Project by lawrence posted 07-04-2012 04:22 AM 1806 views 4 times favorited 12 comments Add to Favorites Watch

I was asked by an outbound buddy to make a helmet case for him. He didn’t like the standard “made in China” ones that we’ve been getting for folks’ going away gifts and asked if I could make something a little more personalized. To fit into his budget, I had to be able to make it in about 10 hours, and I just about nailed it (officially in my project journal I have 10.75 hours in this job) The wood (mahogany) was free as it was part of a large “freecycle” lot that I got a while back.

I stained the mahogany with gel stain and then sprayed it with lacquer before assembly. The glass is in grooves and is held in place with silicone adhesive. The top and bottom of the glass enclosure are mitered and pinned to the rails. The bottom portion was personalized with my Carvewright. After carving, I sprayed the carvings with black ink, then planed them off to leave the black in the background. I then stained and lacquered the base. I cut the vinyl resist for the etching with my silhouette CNC paper cutter and etched the glass using 150 grit aluminum oxide and a $50 harbor freight pressure pot sprayer.

Overall, I’m quite pleased with the outcome and hope he will be too.

Thanks for looking, and as always- your encouragement or constructive critiques are always appreciated

12 comments so far

View BenI's profile


331 posts in 1270 days

#1 posted 07-04-2012 06:32 AM

Very nice looking piece. Like the way you did the bottom, personalized part.

-- Ben from IL

View Ken90712's profile


16047 posts in 2281 days

#2 posted 07-04-2012 07:59 AM

What a cool and great job! You nailed it!!!!

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

View Jamie Speirs's profile

Jamie Speirs

4166 posts in 1948 days

#3 posted 07-04-2012 08:18 AM

It has class

Looks really good


-- Who is the happiest of men? He who values the merits of others, and in their pleasure takes joy, even as though 'twere his own. --Johann Wolfgang von Goethe

View waho6o9's profile


6397 posts in 1669 days

#4 posted 07-04-2012 02:56 PM

Most excellent work Lawrence, and under 11 hours?

That’s crazy cool, good job. A favorite for sure, thanks for posting.

View Lee A. Jesberger's profile

Lee A. Jesberger

6793 posts in 3072 days

#5 posted 07-04-2012 03:07 PM

Hi Lawrence;

Excellent job.


-- by Lee A. Jesberger

View a1Jim's profile (online now)


113838 posts in 2669 days

#6 posted 07-04-2012 03:51 PM

Wow this is very cool,I like the case and great etchings too.

-- Custom furniture

View Gpops's profile


247 posts in 2536 days

#7 posted 07-04-2012 04:02 PM

Great job, and a special thanks for those who serve and served to keep the USA free on this the Fourth of July!!!!!

View Northwest29's profile


1281 posts in 1582 days

#8 posted 07-04-2012 04:58 PM

Well, you certainly did an excellent job of making it look like a NOT made in China case. Great job! Where the vertical corner posts meet the top frame – how are they joined together?


-- Ron, Eugene, OR, "Curiosity is a terrible thing to waste."

View lawrence's profile


53 posts in 2095 days

#9 posted 07-04-2012 05:50 PM

Thanks all, I really appreciate the support.

Ron, the top and bottom “frames” are mitered pieces like 2 picture frames (no glass in the bottom piece) The glass is held in grooves in the frame/rails with silicone adhesive. Additionally, I drilled pilot holes into the rails through the top and bottom frames and pounded in (gently) pegs (toothpicks) dipped in epoxy.

Thanks again all, this was a fun project.


View twoblacklabs's profile


228 posts in 1784 days

#10 posted 07-05-2012 01:08 AM

Very nice. Going to have to send link to my big brother. Retired off of AC130’s but is back at it again.

-- If You Haven't Got the Time to Do It Right, When Will You Find the Time to Do It Over?

View Sam Shakouri's profile

Sam Shakouri

1095 posts in 2180 days

#11 posted 07-05-2012 01:49 AM

CONGRATULATION for DT3. Very nice case.

-- Sam Shakouri / CREATING WONDERS WITH WOOD.....Sydney,Australia....

View Derek Oliver's profile

Derek Oliver

113 posts in 1243 days

#12 posted 07-06-2012 10:23 PM

Everything about this case is impressive from the carving, to the echting and especially that you were able to complete it in less than 11 hours.

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